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ARC WELDING 


The New Age 


in 
Iron and Steel 


Price $1.50 


~ 632 


PUBLISHED BY 


THE LINCOLN ELECTRIC COMPANY 
CLEVELAND, OHIO 


Copyright, 1926 by 
THE LINCOLN ELECTRIC CO. 
All rights, including translation, reserved for all countries including the Scandinavian countries. 


Printed in U.S. A. Published November 1926 


[924 

Table of Contents 
Chapter ) Page 
I), The New Age of Steel. . 0c 0 a2 ana. se pis 
Addenda. steels y ersus: Gast iron a ee. 23 
Litre Ae eres | Makes Rav ating dat lie Pantene neater tne 31 
III. What ns Welding i is s and What it Does. : os : rope aes 
Addenda. Oris ‘Methods Nt Weldine.. = ee 3 2 aes 
AN ee Fok ae Welding in General “Manufacturing.” 0). 57, 
V.. Strength of Arc Welded Joints.;.7.%. 7.3. enneene 11 
VI. <The Speed-and (Cost cr yy idiot eee Gui ee ee 123 
VII. Automatic Arc Welding... ... 1. 3:5. 139 
Advertising ase paises bene at he glee ie Pe 


Page 2 


CHAPTER I 
The New Age in Iron and Steel 


|P) eae the first quarter of the twentieth century we have 
entered a new age in the use of iron and steel. 


It is an age in which all things fashioned from iron and steel 
will be finer, stronger and better, yet they will be produced for 
a fraction of their former cost. 


It is an age in which the established methods and traditions 
of metal working will be cast ruthlessly aside. Sweeping 
changes in designs and processes will be the inevitable result in 
every plant where iron and steel is used as raw material. 


These basic changes in the world’s greatest industry are even 
now resulting from the use of electric arc welding. 


This statement is made in full knowledge that it will be chal- 
lenged by men who have cath their lives in working these great 
metals. 


It is a matter of history that those who will he most affected 
by any great change are the last to see it coming. The sailing 
masters were among those who scoffed most at Fulton’s new 
steamboat, and no one laughed so long or loudly as did the 
buggy maker when Henry Ford brought out his first horseless 
carriage. 

By the same token America’s greatest fortunes have been 
built by the few men who could see such new developments and 
sense their significance before their fellows. 


Electric arc welding offers just as certain an opportunity for 
‘profit to those far-sighted manufacturers who will study its 
possibilities with an open mind and a firm determination to 
apply it to their own products. | 


CAST IRON, 908 POUNDS 
Fig. 1 


ARC WELDED STEEL, 395 POUNDS 
Fig. 2 


S. R. Dresser Manufacturing Co., Bradford, Pa., save over half the weight by making 
this split sleeve of arc welded steel instead of cast iron. These split sleeves are used 
in the oil fields and freight is a big item on many of their products. Arc welding 
cuts the freight bill in half. The manufacturing cost is also greatly reduced and 

the product is more reliable. 


Page 4 


Statement of Advantages and Method of Proving 
the Victory of Steel Over Cast Iron 


Cast iron as a material for manu- 
facturing machinery is much inferior 
to steel in all ways—in fact, steel 
makes the present industrial age 
possible. There is practically no 
mechanical advance now existing 
which would be possible if the cast 
form were the only one that iron can 
take. The railroad, steamboat, auto- 
mobile, telephone, radio, and air- 
plane are all impossible in the light 
of cast iron only. Civilization would 
go back to the dark ages without 
steel, yet all things now made from 
cast iron can be equally well pro- 
duced from steel. 

We are dealing, however, with a 
world where both cast iron and steel 
may be used by the designer and this 
book has to do with the economics 
of the question only. 

Rolled steel for machine manu- 
facturing has four fundamental ad- 
vantages : 

1. Steel costs one-third as much 
per pound as cast iron. 

2. Steel is approximately six 
times as strong in tension as cast 
iron (working strength). 

3. Steel is two and one-half times 
as stiff as cast iron. 

4, Steel is more uniform. There- 
fore, a smaller factor of safety can 
be and is always used for equal 


Steel 


| 2.5 


Cast Iron ; 
Fig. 3 


Steel is two and one-half times as stift 
as cast iron. 


STEEL 


DEFLECTION 


safety than for cast iron. 

There are other advantages of 
great importance from a cost saving 
standpoint which are discussed, but 
the above four reasons are the 
fundamentals. 

Cast iron has been used hereto- 
fore because it is easy to cast into 
any shape, hence its fundamental 
unsuitability to the purpose has been 
overlooked, but the arc welder has 
made it possible to form standard 
steel shapes into practically any 
form and the last reason for its con- 
tinued use has disappeared. When 
it is remembered that steel also is a 
much more suitable and less costly 
material, the rapid change from cast 


WWW. 


CAST IRON 


DEFLECTION 


> 
» § 


Fig. 4 


Steel is six and one-half times as strong 
as cast iron in tension. 


NOTE—A complete semi-technical discussion of the relative strength and economy of steel 
as compared with cast iron will be found at the end of this chapter on pages 23 to 29. 


Page 5 


Where arc-welded steel is substituted for cast iron, no patterns or core boxes are 
needed. All five motor frames and rotor spiders are made from the six standard 
steel shapes illustrated. 


Fig. 5 
This means that a much smaller material inventory is required because the steel 
jobber carries all of these shapes in stock. Furthermore much less storage space is 
required. The illustration shows all material for the five motor frames and rotor 
spiders loaded on one shop truck. The total manufacturing cost is cut in half. 


Page 6 


iron is assured. 

Other advantages which naturally 
flow from the substitution of steel 
for cast iron are: 

a. Cutting cost of development of 
new design. 

b. Elimination of pattern expense. 

c. Elimination of obsolete parts. 

d. Reducing of cost and amount of 
necessary machining. 

e. Reducing of building space for 
the same output. 


f. Reducing of the raw material in- 
ventory and the total material 
cost. 

The sum of all these savings will 
average at least one-third of the cost 
of any product now made from cast- 
ings if it is large enough so that 
structural steel can be applied to it, 
and many cases have come to the 
writer's notice where savings much 
in excess of sixty percent have been 
made by the substitution. 


Fig. 6 
ROTATING TABLE 


A little ingenuity plus an arc-welder make it possible to substitute arc-welded steel 


for almost any casting at a distinct saving in cost. 


Here is a rotating table made of 


standard steel shapes. 


Page 7 


THE DEVELOPMENT OF AN IDEA IN CAST IRON 


——— rice 28 oe 
a cae 
: AY), 
yy fo? ag 
=) 
Make mold and. os if SOS 


pour casting. 


OOS EA im 


| 


Assemble complete product. AD 
be THE DEVELOPMENT OF AN IDEA IN or 
fe ARC-WELDED STEEL <2 


Fig. 7 
The welder works direct from rough sketches, often eliminating all machine work and 
always reducing the time and cost of assembly. 


. Page 8 


Cutting Cost of Developing New Designs 


. How large the item of ‘“Develop- 
ment Work” looms in many an op- 
erating statement! How many 
firms could show a substantial profit 
if this item could be cut down in 
their annual budget! 

Consider, for instance, the de- 
velopment of an idea in cast iron: 

A manufacturer desires to de- 
velop new models. Days are spent 
-on the drafting board—days are 
spent in the pattern shop—more 
days in the foundry—and when 
thousands of dollars in time and 
money have been invested the first 
model is ready for test. Too often 


the tests are unsatisfactory and the 
whole costly process must be re- 
peated. 


Contrast such a proceeding with 
that where arc welding is intelli- 
gently employed. 


Rough sketches can go direct 
from engineering to welding shop. 
Patterns are unnecessary. Actual 
working models can often be brought 
together in a few days’ time. 


Think of the saving in invest- 
ment and the saving in valuable 
time in putting a new design on the 
market! 


Fig. 8 


This annealing oven was built complete by arc welding. No detailed drawings were 


made. 


Forty-nine hours after rough sketches were given to the welding foreman the 


oven was ready for the brickwork. This oven is one of four recently built by The 
Morgan Engineering Company. 


Page 9 


These plates and bars welded into a single piece make up the top of the turntable 
shown below. 


Fig. 9 


TURNTABLE FOR AUTOMATIC MACHINE 


There is no pattern expense to be charged against this job. The base and turntable 
are made of standard bars and plates, arc-welded for strength and economy. 


Page 10 


Fig. 10 


The pattern storage of a well known manufacturer before adopting arc welding. 


Elimination of Pattern 
Expense 


Nor does the saving stop here. 
The interest on the investment in 
patterns, the expense of their stor- 
age, repair and insurance are items 
which can be largely eliminated 
where the product is welded in steel. 


Page II 


Fig. 11 


Why use castings for sheave blocks re- 
quiring a separate pattern for every size 
and styleP Arc-welded steel is stronger, 
lighter and cheaper. Any size or style 

can be made from standard steel shapes. 


Fig. 12 


Arc-welded steel will supersede cast iron for making bases for machinery of all 
kinds. Since steel is twice as rigid as cast iron the saving in weight is apparent. 
Illustration by the courtesy of The Parks Ball Bearing Machine Co., Cincinnati, O. 


Fig. 13 


The base of this dynamometer is extremely rigid. It was also cheaper to 
build than a cast-iron base. 


Page 12 


Lower Material Inventory 


The manufacturer who uses cast 
iron must in self protection carry a 
heavy inventory of all the different 
castings which may be called for on 
any of his models or designs. 

Very often this item is equivalent 
to a large percentage of his capital 
investment. It is an item which he 
must frequently borrow money to 
cover while the parts lie idle and 
profitless in his storage. 

By contrast the manufacturer 
who builds his product from steel 
needs only a small stock of the 
different standard steel shapes he 
uses from which his welding de- 


partment can fabricate in a few 
days the necessary supply for any 
order. 

This is because any one of a large 
number of different parts can be 
made up of standard steel shapes of 
the same size and style whereas a 
casting can seldom be used for any 
purpose other than the one for 
which it was designed. 

In actual practice one manu- 
facturer of a large line finds that 
his inventory of steel is less than 
eleven percent of the amount he 
used to carry tied up in iron cast- 
ings. 


Fig. 14 


This small stock of standard steel shapes replaces a casting storage covering about 
one-half acre. 


Page 13 


Fig, 15 s—Os 
Arc-welded steel replaced cast iron in the manufacture of this turbine pressure blower 


manufactured by the Robinson Ventilating Co., Pittsburgh, Pa. The welded steel 
base is lighter, stiffer and cheaper to build. 


Fig. 16 


This combination circular rip and cross cut saw, 12 inch joiner and boring machine is 

supported by a frame of arc-welded steel. Strength, lightness and economy are the 

results. This is only one of the uses that the Parks Ball Bearing Machine Co., Cin- 
cinnati, Ohio, makes of arc welding. 


Page 14 


No Obsolete Parts 


The organization has not yet been 
found that can estimate exactly the 
number of any given model that will 
be built nor even the number of 
parts of each kind that are needed 
for a given production. 

Finally with the best of esti- 

mates, breakage and mis-machining 
are to be reckoned with. And so it 


comes about that with the discon- 
tinuance of certain designs there 
are left many hundreds of obsolete 
castings which at best can be in- 
ventoried only at scrap value. 

This annual waste has been almost 
entirely eliminated in plants where 
welding is used to the fullest ex- 
tent. 


Fig. 17 | 
ROTOR SPIDER FOR ELECTRIC MOTOR i 


Cast Iron, Wt. 7014 Lbs. 


Cost of rough casting___-____------ $6.75 
Peaharmcorte ne 2200. ie ool. n a 2.94 
ee COAT ee eee $9.69 


-Arc-Welded Steel, Wt. 4314 Lbs. 


2 Cost. of rolled steel______________-_$1.28 
7a ADOT 4 COST ee ee ee 4.37 


Total cost DAU Gaate AN «ge ee GS 


Double elevator machine for use in a paper mill. The base of this machine is 19 feet 
long and is built of standard shapes joined by arc-welding. 


Page 15 


Fig. 19 Fig. 20 
END RING ON MOTOR 


CAST IRON ARC-WELDED STEEL 
Cost of rough casting_____________- $2.89 Cost of rolled steel__________ Pal! $1.126 
Labor -cost (2, 22 ee a oe 195 Labor cost 22222 407 
Total.-cost 20 ee ee $3.085 Total cost. soc. e $1.533_ 


Arc-welded construction costs less than one-half as much as cast iron. 


Fig. 21 


Before arc welding was perfected machine bases were necessarily made by casting 
because there was no other method of getting the required rigidity. Now arc welded 
steel makes a more rigid base at a lower cost. 


Page 16 


Little or No Machining 


Last, but by no means least, is the 
cost of machining cast iron to finish 
surfaces or for the necessary fit. 
This cost in large part is eliminated 
in welded steel where the surface is 
already hard finished by rolls and 
the sizes are so accurate as to de- 
mand no machine work. 


When it is necessary to machine 
rolled steel the part can be finish 
machined without allowing weeks 
or months to elapse between the 
roughing and finishing cuts. There 
is no necessity for seasoning as 
there are no locked up strains in 
rolled steel such as are so objection- 
able in cast iron. 


Fig. 22 


Contrast the appearance of this rigid arc-welded steel base with the bulky, clumsy 


cast iron base generally used for machines of this nature. 


The arc-welded base is 


stronger and cheaper. 


Page 17 


Fig. 23 


Large foundry space required by manufacturer before adopting arc welding. 


Fig. 24 


The small welding shop required to make the same parts. 


Page 18 


Less Building Space But Greater Production 


What would it mean to the aver- 
age manufacturer if he could in- 
crease his production 100% in im- 
portant departments and at the same 
time cut in two his floor space? 


Such radical savings are not 
theoretical possibilities, they are 
actually being made in plants where 
important parts of the product are 
now made by arc welding instead of 
by casting. 


» Take, for instance, the produc- 
tion of certain frames averaging 20 
inches in diameter and 3 inches 
thick. These were formerly made 
in a foundry where a production of 
60 per day required a molding 
floor space of 600 square feet to 


say nothing of pig iron storage, 
tumbling barrel room, pattern stor- 
age, etc. Today that same frame is 
made by simply rolling a standard 
steel angle to circular shape and 
welding the ends. 


The total floor space for the en- 
tire operation including storage of 
stock does not exceed 300 square 
feet. 


The present cost of construction 
is such that no progressive execu- 
tive is overlooking such an oppor- 
tunity to make his present floor 
space more productive. 

Here again is that inevitable eco- 
nomic force which is ushering in 
the new age in iron and steel. 


Fig. 25 
MOTOR BASE RAILS 
ARC-WELDED STEEL 


CAST IRON , 
Cost of rough casting_________--__$4.992 
fen OtMeOSt ee oa) ) al 117 
el ECOstte =. te $5.109 
SWetstitew eh sce ok ak kk 77 Ibs 


Cost of rolled steel_____._.-._--- $1.536 
Dabor: costes oo ee eee 617 

‘otal cost.2-_.. ee $2.153 
Weight: eee = etree aes 66 Ibs. 


\ Fig. 26 


The cost of making this huge manifold of cast iron would be enormous. By arc weld- 

ing both the weight and cost are materially reduced. Oil refining equipment of every 

sort is now arc welded. Photograph by courtesy of the Power Piping Company, 
Pittsburgh, Pa. 


Page 20 


Why is Cast Iron used when Steel is better and cheaper? 


With all of the undeniable ad- 
vantages which steel has over cast 
iron the question must arise as to 
why industry has not discarded cast 
iron entirely except for a few spe- 
cial applications. The only answer 
is tradition. 

It is remarkable the extent to 
which tradition and custom rule our 
lives. The first railroad passenger 
cars were simply stage coaches on 
rails, 

For many years the automobile 
was merely a glorified buggy instead 
of a new vehicle to be used under 
entirely new conditions. 

It seems to be an unwritten law 
in designing any new product to 
make it look like the old rather than 
frankly to consider its purpose and 
then build it to suit that purpose. 

Thus it has become tradition that 
a machinery base, for instance, must 
be a rectangular bulky piece of cast 
iron difficult to cast, needlessly 
heavy to ship, and unnecessarily 
high in cost. 

We have.a feeling that the sec- 
tions of metal must be heavy and 
clumsy and that corners must be 
rounded—that supporting bases or 
pillars must taper from bottom to 
top. 

All of this is nothing more nor 
less than tradition. For years we 


YE~<lpi 


ea 
CD 


have been used to the bulky shapes, 
heavy sections, rounded corners, 
and tapering members. Why? Be- 
cause cast iron had to be bulky to 
get sufficient strength, and it had to 
be tapered and rounded in order to 
draw the pattern from the sand 
successfully. 

Today with hundreds of examples 
in welded steel before us, there is 
no logical reason in the world for 
clinging to the old designs which 
were necessary owing to limitations 
of the casting process. 

As an example of this consider a 
design in which it is desired to se- 
cuire a very rigid pillar or base. The 
shape which will give the greatest 
possible rigidity or stiffness per 


pound of metal is the I-beam. 


I-beams with the proper propor- 
tions to give maximum efficiency are 
stock items in rolled steel. It is not 
feasible, however, to make an 
I-beam of cast iron because of the 
impossibility of getting the proper 
proportion between the web and the 
flanges. Shrinkage and moulding 
difficulties practically debar the use 
of this most useful shape in cast 
IZOn, es. 

There are thousands of cases like 
this where an inexpensive structure 
made from standard steel shapes is 
better in every way than the tradi- 
tional cast iron. 


Fig. 27 


Tradition was responsible for the looks of the early automobiles. 


They were made to 
look like buggies instead of being designed to meet entirely different conditions. 


Page 21 


Fig. 28 


Equipment for oil refineries is now built largely by arc welding. This condenser or 

harp is used to condense the hot gases as they come from the oil still, and has to 

withstand high pressure and heat. Arc welding reduces the cost of making this 

equipment to less than half of the cost of any other method. Note how this condenser 

is built up of standard sizes of pipe all welded together into integral parts. Built by 
the Power Piping Co., Pittsburgh, Pa. 


Page 22 


ADDENDA TO CHAPTER I 
Steel Versus Cast Iron—The Technical Facts 


The use of cast iron is so general 
throughout all industry that at first 
glance one is apt to question the startling 
statements made in the foregoing chapter 
regarding the economy of substituting 
arc welded steel for cast iron. Any one 
who will follow the semi-technical dis- 
cussion in the next few paragraphs can- 
not but be convinced that these state- 
ments are entirely correct and that in 
90% of the places where cast iron is 
now used arc-welded steel would be better 
and cheaper. 


Fig. 29 
Cast Iron. 


Microphotographs of cast iron and steel. 


The Structure of Cast Iron 
and Steel Compared 


The two micrographs in figures 29 and 
30 show the essential difference between 
cast iron and steel as regards structure. 
Both steel and iron contain carbon. ‘]he 
difference is that in cast iron the carbon 
is segregated into curved plate-like shapes 
distributed through the mass, while in 
steel the carbon is chemically combined 
with the iron. In cast iron these carbon 
spots are weak and break up the homo- 
geneity of the metallic structure. As far 
as strength of the cast iron is concerned, 
these carbon plates might just as well be 
holes. 

In steel, however, the carbon in com- 
bination is found in the boundaries of 
the metallic crystals. This boundary 


material, unlike the carbon plates in cast 
iron, is stronger than the crystals them- 
selves. ‘This. carbon-iron mixture forms 
a cement tougher than the aggregate or 
crystals of pure iron. 

It is apparent from these photographs 
that steel is more uniform and homo- 
geneous in structure than cast iron. Let 


us consider next the resistance which 
these two metals offer to various kinds 
of stress to which they are subjected in 
compression, 


practice, namely, tension 


and bending. 


Fig. 30 
Steel. 


Magnified 100 diameters. 


Steel is Stronger Than Cast 
Iron in Compression 


Tables of strength of materials give 
the compressive strength of cast iron as 
90,000* Ibs. per sq. in., and the compressive 
strength of steel as 55,000 Ibs. per sq. in. 
This apparently indicates that cast iron 
is stronger than steel in compression. 
Let us examine the facts more closely. 
The figures given above do not repre- 
sent the safe working limits but instead 
represent the ultimate or breaking stress. 
Naturally, in practice, metal is not 
stressed to .the breaking point. The 
maximum allowable stress beyond which 
it is unsafe to go is found by dividing 
the ultimate strength by a number called 
the factor of safety. Sound engineering 

*“NMechanical Engineers Handbook”—Marks. 


Page 23 


Fig. 31 


These arc-welded door frames and manholes were formerly made of castings. Arc 

welded construction eliminates pattern expense which is a large item where only one 

‘or two similar parts are needed. The photo below shows these fittings welded in 
place. Photographs by courtesy of Downington Iron Works, Downington, Pa. 


practice stipulates the following factors 
of safety for cast iron and steel under 
various kinds of load. 


PRULORS OF SAFETY 


Material Kind of Load 
Steady Varying Shock* 

ECS te ae 6 10 20 

Structural Steel .,.. 4 6 10 


The safe working stresses for steel and 
cast iron in compression, obtained by 
dividing the ultimate stress by the proper 
safety factor, are tabulated below: 


COMPRESSIVE WORKING STRESS 
IN LBS. PER SQ. IN. 


Material ' Kind of Load 
Steady Varying Shock 
ase TON. os... « 15,000 9,000 4,500 


Structural Steel....13,750 9,166 5,500 
It is now apparent that for actual 
working stresses, steel is superior to cast 
iron for any service where the greatest 
stress is compression and the load is a 
typical machine load which varies. 

Now let us consider the relative cost 
of cast iron and steel for compression 
members. Since steady loads are seldom 
encountered in machine practice a vary- 
ing load is taken for this example. As- 
sume a load of 100,000 lbs. to be carried 
on a block 2 inches thick. A cast iron 
block to take this load would have to 
have an area of 100,000/9,000 or 11.1 sq. 
in. The weight of this cast iron block 
would be 534 Ibs. and at 6 cents per lb. 
would cost 34 cents. 

A steel block to take this load would 
have an area practically the same. The 
weight of the steel block would be 63 
Ibs. and at 2 cents per lb. would cost 12.6 
cents. 

Thus, by substituting steel for cast 
iron there is a saving of 63% in mate- 
rial cost. 

It is apparent from the foregoing that 
steel is both stronger and cheaper than 
cast iron for compression members 
where varying loads are encountered. 


Steel is Stiffer Than Cast Iron 
.in Bending 

There is a widespread tradition that 
cast iron is stiffer than steel, that is, that 
it deflects less under the same load. The 
fact is that steel is 2%4 times as stiff as 
cast iron when subjected to bending. 

This is shown by the modulus of 
elasticity of each. The modulus of 
elasticity of steel is 30,000,000 while the 
modulus of elasticity of cast iron is only 
12,000,000. Translated into non-technical 
language, this means that if a steel beam 
carrying a load and sagging a certain 
amount were changed to cast iron of 
the same dimensions, the sag of the cast 


*Data from ‘‘Elements of Machine Design” 
by O. A. Leutwiler. 


Cast Iron 


BCR eae 
Steel 
Fig. 33 - 
Steel is more dependable than cast iron in 
compression and it costs less. 
Sections of equal strength 


iron beam would be 2% times as great as 
that of the steel beam. That is, it would 
sag 2%4 times as much, provided it did 
not break because of its lesser strength. 

Therefore, if a cast iron section in 
bending were replaced by an equal sec- 
tion of steel, the sag or deflection would 
be reduced by 60% and the cost would 
be one-third as much because of the low- 
er cost per pound of steel. 

Ordinarily, however, the designer 
would wish to take advantage of the 
superior strength and stiffness of steel 
by reducing the section and thereby mak- 
ing the cost approximately thirteen per- 
cent, or a saving of eighty-seven percent 
if the most efficient steel shape is used 
for the replacement. 

This can be done in practically every 
instance because any shape which can 
readily be cast in iron is not of the best 
design to withstand bending stresses. 


Equal Stiffness is Not the Same 
as Equal Strength 


_ In substituting steel for cast iron in a 
part subjected to bending, we must take 
into account not only the relative areas 


Page 25 


Fig. 34 


Arc-welded steel blower fans are lighter “5 25 

: Fig. 35 
than cast iron fans and stronger than : 
riveted steel fans. They are also cheaper Welded steel annealing reel manufactured 
to manufacture. Photograph by courtesy by The American Pulley Company, Phila- 
of the Robinson Ventilating Co., Pitts- delphia, Pa. 
burgh, Pa. 


The Industrial Controller Company, Milwaukee, Wis., make their Compensator Cases 
of arc-welded steel. This method is cheaper and better than riveting or casting. N 


Page 26 


of the sections of cast iron and steel, but 
also the shapes of the sections. It is 
common knowledge that a board is 
stronger and stiffer if bent edgewise 
than if bent flatwise. Strength and stiff- 
ness in bending are obtained by keeping 
the material of the section as far from 
the center as possible. The I-beam and 
channel illustrate this principle. Their 
great strength and stiffness are due to 
the material in the flanges, located at a 
distance from the center of the section. 
This principle is illustrated in Figure 36 
where a cast iron section is replaced by 


three different steel sections, each one . 


having the same vertical stiffness as the 
cast iron section. While the vertical stiff- 
ness is the same in each of the sections 
illustrated, the weight, working strength 
and cost vary considerably. These values 
on a percentage basis are tabulated under- 
neath the sections to which they apply. 
The effect of changing the vertical and 
horizontal dimensions separately is clear- 
ly shown by this illustration. It is 
assumed, of course, that when one hori- 
zontal dimension is changed, all hori- 
zontal dimensions are shrunk in the same 
proportion. The same assumption is 
made when vertical dimensions are 
changed. 


Steel is Stiffer Than Cast Iron © 


in Compression 


Thus far we have considered the rela- 
tive stiffness of steel and cast iron only 
when subjected to a _ bending stress. 
Steel is also stiffer than cast iron when 


subjected to compression. This is shown 
by referring again to figure 33, where a 
load of 100,000 Ibs. was assumed to be 
supported on a block 2 inches thick. 
Under this load the cast iron would de- 
flect or in other words be compressed 
1.8 thousandths inches. The steel block of 
same area and the same thickness would 
deflects only .68 thousandths inches. Not- 
withstanding that the steel block was 
stressed the same, the deflection is less 
than one-half that of cast iron. 


Steel is Stronger Than Cast 
Iron in Tension 

There remains only to be considered 
the relative strength and economy of steel 
and cast iron in tension. The ultimate 
strength of steel in tension is 55,000 Ibs. 
per sq. in., while that of cast iron is 
only 15,000 Ibs. per sq. in. These are the 
ultimate or breaking stresses. To deter- 
mine the working stresses these figures 
are divided by the proper safety factors 
which gives the following: 


Tensile Strength 
CastIron Steel* 
Ultimate Strength.. 15, mn 55,000 
Factors of Safety.. 6 
Working Stress.... ji 300 9,166 
Modulus of 
Elasticity ........12,000,000 30,000,000 


These figures show that in tension the 
allowable working stress of steel is ap- 
proximately 6 times the allowable work- 
ing stress for cast iron. This means 

*“Wechanical Engineers Handbook’’—Marks. 


SECTIONS OF EQUAL VERTICAL STIFFNESS 


——_——, 


a wos Bees a0 70-4 + —— 100% mec eee ~*—+ 


B C 
CAST IRON STEEL STEEL STEEL 
Shrunken ir hrae: cla 
Width eight Height 
mtiiinese cs. ee ssf 100% 100% 100% 100% 
Wieishtaee a co 100% 40% 73% 63% 
Working ee nc 240% 320% 296% 
Ot nee. eS. 100% 13% 24% 21% 
Fig. 36 


Page 27 


Fig. 37 


Fig. 39 .» 


This arc-welded steel dip pot was form- 
erly made of a casting. There is no ex- 
cess metal in arc welded construction. 
Weight is saved and the cost per pound 
of rolled steel is less than cast iron. 
Photographs’ by courtesy of Downington 
Iron Works, Downington, Pa. 


Fig. 38 


Steel has replaced cast iron in countless 

products used in wire drawing and in the 

textile industry. Here are two examples 

made by the Mossberg Pressed Steel Cor- 

poration, Attleboro, Mass. Both are arc 
welded. 


Fig. 40 


Gear guards of arc-welded steel are re- 

placing cast iron and riveted steel guards 

because they are cheaper to make, ‘are 

lighter and withstand vibration better. 

Illustration by the courtesy of the Whit- 
ing Corporation, Harvey, III. 


Page 28 


that where strength in tension is the only 
consideration, a cast iron section can be 
replaced by a section in steel just 17% 
as large. 


Assuming the cost of cast iron at $.06 
per lb. and steel as $.02 per Ib., or 334%4% 
of the cost of cast iron, the relative cost 
of steel is 3344% x 17% or 5.66% that 


of cast iron. 


Great care must be exercised at this 
point because, while steel is 6% times as 
strong as cast iron in tension, it is only 
2% times as stiff. This means that 
when substituting steel for cast iron, it 
is important to know whether the steel 
is to be as strong as the cast iron section 
or as stiff as the cast iron section. It is 


EQUAL TENSION LOAD 


CAST IRON 
COST 100% 


SECTIONS FOR EQUAL STRENGTH 


obvious from the foregoing that when a 
section in tension is cut down to 17% 
when steel is substituted, that the 17% 
steel will not be as stiff as the 100% of 
cast iron even though it is equally 
strong. Instead, 40% of steel will be as 
stiff as 100% of cast iron as was 
demonstrated earlier. The data presented 
here can be verified in any text book on 
the strength of materials, and is common 
knowledge to every engineer. 


The fact is that there was no way to 
cash in on the greater economy of steel 
until arc welding was perfected because 
there was no economical method of join- 
ing steel shapes. Today, steel can be 
substituted for cast iron at a saving in 
nine cases out of ten. 


EQUAL BENDING LOAD 


STEEL 
COST 13% 


| 
100 SQN. 


CAST IRON 
_ COST 100% 


SECTIONS FOR EQUAL STIFFNESS 


Fig. 41 


For equal working strength in tension, replace cast iron by 17 percent of that 


section 


in steel. 


For equal stiffness of deflection in tension, replace cast iron by 40 percent of that 
section in steel. 


Table of Comparison of @ualinesiat Cast Iron and Steel 
for Machine Parts 


Strength 


Allowable working stress including factor 
of safety—6 for steel, 10 for cast iron 9,166 
Cost equal strength including factor of 


safety 


MeTIteTOs CIASUICITY: «0. keke el eee es 
Peta WaDle CETICCLION. «6.6. . wa ce ake eos 
Cost equal rigidity for shrunken width.. 


These figures are based on varying load conditions. 


eocecereeceeoere eee eee se we ee ee ee eH eo 


eoeereeere rere ee eee ee eeoeeeeee eee 


Tension Compression 

Steel ‘Cast Iron Steel — Cast Iron 
55,000 15,000 55,000 90,000 
1,500 9,166 9,000 
5.6% 100% 32% 100% 
Bending 7 

Steel Cast Iron 

Ae. 9h eee 30,000,000 12,000,000 
he an ere Same Same 
ee EY Ser ey 13.3% 100% 


If the same computation 


is made for a steady load the ratio of cost of steel to cost of cast iron will be ap- 


proximately the same. 
would be even greater. 


Under a shock load the advantage of steel over cast iron 


Page 29 


Here is a Common Sense Problem in Manufacturing 
Costs and Profits 


Suppose you are making a product of cast iron. 
If you buy your castings outside: 


1. You must pay an average price of 6 cents per lb. for them. 


2. Your material cost amounts to a large proportion of your manu- 
facturing cost and of your selling price. 

3. Over this large portion of your costs you have no control. Some one 
else determines what this part of your cost shall be. 


The various items which make up the selling price would look something 
like this. 


35% | 8%) 1 % 31% 


RAW MATERIAL ‘LABOR SHOP SELLING AND PROFIT 
OVERHEAD ADMINISTRATION 


But if you substitute arc-welded steel for cast iron: 


1. Your raw material cost is 2 cents per lb. 

2. The weight of raw material required is less. 

3. The total cost of raw material is greatly reduced. 

4. And a much larger proportion of your total manufacturing cost is 
under your control. 


The various items which make up the selling price would now look 
like this. . 


RAW MATERIAL LABOR SHOP SELLING AND PROFIT 
OVERHEAD ADMINISTRATION. 


In this example 80% of the total selling price is made up of items over 
which you have control instead of only 65% as is the case where castings 
are bought outside. These figures are purely arbitrary, but the principle 
is correct. Substituting arc-welded steel for cast iron cuts costs and 
increases profits. 


The fact that one’s own foundry is used does not solve the trouble since 
the raw material cost will still be much greater with cast iron than with 
steel. 


Page 30 


CHAPTER II 
Arc Welding Makes Riveting Obsolete 


HE  sky-scraper, the huge 

bridge, the ocean greyhound of 
the future, will each be safer and 
stronger because of arc welding. In- 
stead of being constructed of many 
separate plates and shapes pegged 
together with rivets, the frame 


work of each will be one solid piece 
of steel welded into a homogeneous 


whole by the magic of the electric 
arc, 


Like the famous one-horse shay, 
each part will be as strong as the 
next because in arc-welded construc- 
tion the joints are as strong as the 
members to be joined. This is not 
possible in riveted construction. 


Fig. 43 

Arc-welded steel bridge in Toronto, Ont. The steel frame work carries the entire 

load, concrete is used solely as a protection for the steel. The detail shows methods 

of butt welding the members. As an additional precaution a collar was slipped over 

the joint and welded in place. The cost of the arc-welded construction was far below 
that for any other type of construction. 


Page 31 


Fig. 44 


Arc welded swimming pool in the new Standards Club, erected by the Graver 
Corporation, East Chicago, III. 


SPEER TARRS 


Fig. 45 


The storage tanks for fuel oil, gasoline and distillate manufactured by The Novelty 
Steam Boiler Works Co., Baltimore, Md., are unconditionally guaranteed. Heads 
and girth seams are arc-welded. 


Page 32 


Fig. 46 


Rivet holes weaken the plates where the strength is needed most. 


Every Rivet Hole Weakens a Structure 


At present when a boiler or tank 
is built to withstand high pressure, 
the best steel that can be rolled is 
selected. This steel is then taken to 
the fabricating shop where it is 
robbed of its strength by the punch- 
ing of hundreds of rivet holes. It 
is weakened where its strength is 
needed most,—where it is riveted 


to the adjoining plates. 


Arc welding utilizes the full strength of 
the metal. No part of the strength is 
punched out. This ammonia tank was 
made by the Frick Co., Waynesboro, Pa. 


Page 33 


Fig. 48 


This 1,000,000 gallon stand pipe towers 
one hundred and twenty-seven feet in 
the air. It is a familiar land mark to 
the residents of Lancaster, Pennsyl- 
vania. And it is likewise an impres- 
sive monument to the integrity of arc 
welded construction. Welding was 
done by The Lancaster Iron Works. 


Fig. 49 


This purifier box for the Granite City Gas Light and Fuel Co., Granite City, IIl., was 
erected complete in the field by Electric Arc Welding. Built by Steere Engineering 
Company, Detroit, Michigan. 


Page 34 


Riveting Wastes Time in the Drafting Room,— 
in the Shop and in the Field 


Not only does the punching of 
rivet holes weaken the structure, but 
it involves a huge waste of energy 
which modern economic conditions 
will not tolerate. 


Energy is wasted in the drafting 
room where each riveted joint must 
be carefully figured, the size of 


cation of each rivet hole indicated. 


Energy is wasted in the template 
shops where full size cardboard, 
wood or metal patterns of every 
structural member are made and 
every single rivet hole located so 
accurately that when assembled each 


hole will register with a hole in one, 


each rivet determined and the lo- two, or three other members. 
6S: 
BBs 
9 
FUNCHT6 HOLES -REAM FoR 
TURNED GBoLTSs “ 
P-744 x 1-05 


W-W NO/LIIS 


RIV. IN-f#IIN SHOP 


AG-11204-A\THIS SIDE #) SH® 
KG-II1Z05-A FAR SIDES 


*, 3 ’ > 
SSS, SES SS ES, EY, NES, NE EP A wey 
Bae, Y s 
NS 


h--91 1@ @ 20-9, =? ae 

i iv. Sole ‘Ego Reiaieincees te = 
ae 4 3 Pah Sa ; % Ni~ 
ea al 
SAS = 


‘ hd 3" re pl? 
/-L FZKZRABX 3-84- 
| 8-3 0BKR x3-10F 
1) 
i-cHOCK #e-S4xZxo-Ilz 
RIV. ON IN- SRO" 
JACK IS IN PLACE 


LENL-SpIBx O73 


O_O 9 0 0 0 
6 6_b—-6—0B€ 


us 


(EB x3G X27“ 
| I-L-343XEK10-5B-N.S, 
| I~ L-BAZXZV SIFFS, 
7-L- 10-55N S, 
Berge 
x Fs. 


W 
i) 
i) 
Nh 
™ 
) 
n\ 


- 
: 
> 


eo (0 
SYMM ABT E 


Fig. 50 


Think of the time wasted in laying out and punching the rivet holes in this structure. 


Welding will eliminate this waste. 


Page 35 


Fig. 52 , 


\ 


Arc welding is replacing riveting in the manufacture of air ducts, ventilators, smoke 
breechings, conveyor housings and similar products. Here are two examples arc 


welded by Leitelt Iron Works, Grand Rapids, Mich. 
Page 36 


Fig. 53 


| 
| 


y 
| 
, 
Y} 
, 
i 
i 


IN 
LEAS 


| 


Driving rivets is laborious and slow, requiring from three to five men per crew. 


This work requires infinite care, in- 
finite skill—and all is unnecessary. 


More energy is wasted in punch- 
ing the rivet holes, which not only 
weaken the members, but which also 
require expensive equipment and 
labor. There is the tremendous 
economic waste of making every 
member larger and heavier than 
necessary throughout its entire 
length solely to provide the re- 
quired strength at the ends where 
the rivet holes have weakened the 


-member. 


Energy is wasted in driving rivets 
both in the shop and in the field— 
work that is slow and laborious and 


which requires expensive equip- 
ment. 


Fig. 54 


One welder does the work of riveter, 
catcher, heater and bucker-up. 


Page 37 


Fig. 55 


Think of the time and money that it would have taken to rivet together this irregular- 
shaped pipe! McNamara Bros., Baltimore, Md., arc weld tanks of all kinds. An arc 
welded tank requires no calking and the joint is as strong as the plates joined. 


RR 


Arc Welding Saves Material Where Joints Are 
in’ Tension 


An arc welded joint is as strong 
as the members joined.* No part 
of the strength of the steel is 
punched out. The plates or beams 
at the: joint are up to full strength. 
Consequently, it is not necessary to 
make the members heavier through- 
out their length to provide for weak- 
ness at the joint as is the case in 
riveting. | 


It is possible to make tanks 
stronger by arc welding than by 
riveting, using the same weight of 
material, or it is possible to obtain 
equal strength with less material. 

If this saving in material were 
the only advantage of arc welding, 
its importance is so great that this 
modern method would replace the 
old-style practice. 


*See discussion of comparative strength of welded and riveted joints on page 115. 


Fig. 57 


No tanks are too large to be arc welded. This picture was taken at the Heil Co., 
Milwaukee, Wis. 


Page 39 


Fig. 58 


There are 103 arc welded girders in this building. Albert Kahn, Inc., Architect. 


Page 40 


Where Arc Welding Has Replaced Riveting 


The substitution of arc welding 
for riveting is not a vision of the 
future, it is used today on the very 
examples given above, steel build- 
ings, bridges and ocean-going ves- 
sels. 

In Detroit, the steel framework 
of a 12-story addition to the 
Peoples Outfitting Company build- 
ing is arc welded where the floor 
girdets frame into the columns. In 
Canton, a building for the Peerless 
Motor Sales Company was con- 
structed of arc welded steel at an 


estimated saving over riveting labor’ 


cost of approximately 25%. 

In the Province of Ontario, a 
highway bridge of three spans, 500 
feet overall, carrying the heavy 
traffic into the city of Toronto, was 
constructed in 1923, of arc welded 
steel and concrete. The design of 
the bridge is unique. All of the 


steel work is made up of round 
bars. The steel carries the entire 
load, the concrete serving solely as a 
protection for the steel. Before 
this bridge was built the design was 
severely criticized by engineers not 
familiar with the possibilities of arc 
welding. However, the designer 
knew what could be accomplished. 
The bridge was built, and it met all 
required tests, and it was built at a 
cost far below that of riveted con- 
struction. 


Sea-going vessels and lake boats 
have been built complete by arc 
welding, both in this country and 
abroad. Today, that conservative 
arbiter of ship construction, Lloyd’s 
Register of Shipping, is permitting 
the wider application of arc weld- 
ing, as repeated tests demonstrate 
its especial fitness and economy. 


Fig. 59 


Peerless Motor Sales Co., Canton, O. Not a single rivet was used in the construction 
of this building. All of the steel work is arc welded. The Morgan Engineering Co., 
Alliance, O., were pioneers in adopting arc welding for heavy structural work. 


Page 41 


Fig. 60 


Two views of Bottom-dump bucket used for handling rubber. Completely arc welded 
by The Cleveland Crane & Engineering Co., Wickliffe, Ohio. 


Welding Makes a Better Product at a Lower Cost 


It is not only on large spectacular 
work that arc welding is replacing 
riveting. The relative savings are 
equally important in many produc- 
tion industries for welding gasoline 
tanks, automobile truck bodies, 
burial vaults, coal weighing hoppers, 
concrete mixers, truck frames, 
water tanks, etc. 


ietercatiebe tiveted it can be arc 
welded cheaper, faster and better. 
The following pages show a few of 
the many arc welding applications. 
It is manifestly impossible to show 
more than a small percentage. In 


looking over these applications, bear 
in mind that arc welding was 
adopted because it saved the manu- 
facturer money, and made a better 
product. Most of the manufactur- 
ers of these products advertise the 
fact that their products are arc 
welded, because the public is be- 
ginning to realize that a welded 
product is a superior product. 


Whatever you manufacture, if 
iron or steel plays a part in it, arc 
welding can probably be applied to 
advantage. If your product is not 
arc welded now, it will be either by 
your company or your competitor. 


Fig. 62 


Every joint between plates, every outlet flange and every stay bolt on the Ross Steel 
Boiler is arc welded. Ross Boilers are built for 30 lbs. working pressure but are 


tested to 50 Ibs. pressure which is practically the rupture point of the plates. 


The 


Ross Boiler is built by the Frost Manufacturing Co., Galesburg, III. 


ae ae ; 


Page 43 


We cre prox te ba able (0. 


Innounce 


ted Fests’ 


ote og bo 


ERR EY 


pee ok SER DOSTERE BPOLLERS 


THE LARGEST TRUK Tang 
A PHL 


Wade five! 


fe tke eae PE ROL 


Rast e 


Bako. igs the) ee EES. oe Be a 
Beads Soh CDNA ewes Kucey AES BORIS 


Secon siaied SSUSGNT Exoronsyiidh eddy Coredyy dorect 
PH ACAD RL BSR foes 


heed Bo TROY 


Be ; 
. Hovellesx seynt | 


Fig. 63 


An arc-welded product is a superior product. Note the representative manufacturers 
who feature welding in their advertising. 


Page 44 


CHAPTER III 
What Arc Welding Is and What It Does 


HE startling claims made for 

arc welding in the preceding 
pages of this manual are almost be- 
yond belief. To eliminate casting 
and riveting—two fundamental 
manufacturing processes — would 
seem to be a wild and impossible 
vision, but that is exactly what arc 
welding will accomplish. Doubtless 
one’s first thought will be, that to 
bring about such _ revolutionary 
changes, arc welding must be a com- 
plicated process requiring elaborate 
equipment and great technical skill 
for its operation. Fortunately this 
is not the case. 

Before taking up in detail the 
manner in which arc welding is 
utilized in manufacturing, it will be 
well to describe briefly just what arc 
welding is and what it does. 


ae 


There is nothing mysterious 
about the process. The edges of 
the parts to be joined are brought 
to the proper welding temperature 
and fused together. The heat re- 
quired to fuse the metal is developed 
by an electric arc. 

An electric arc is nothing more 
than a sustained spark between two 
terminals or electrodes. In arc 
welding, the arc is formed between 
the work to be welded and an elec- 
trode held usually in the operator’s 
hand. 

The hand electrode may be either 
a metallic wire or a carbon rod. 
Either is held in a suitable electrode 
holder as illustrated in figures 67 
and 68. When the metallic elec- 
trode is used the process is spoken 
of as metallic arc welding, and 
when a carbon electrode is used the 
process is called carbon arc weld- 
ing. Both methods have their par- 
ticular application as explained be- 
low. 


esative Electrode. 


Electrode 


The arc is formed between the work to be 
welded and an electrode held in the 
operator’s hand. 


Electric 


Power 
Fig. 64 


Page 45 


Fig. 65 


There are three ways in which this base for an excavating machine can be made. One 

is by a steel casting, the second by riveted sections and the third by arc-welded 

The arc-welded construction is stronger than riveted construction and 
lighter than a casting of equivalent strength. 


sections. 


Fig. 66 


Rocks weighing more than 1-ton each will be dropped 3 to 4 feet into this heavy-duty 
truck body. It is one of four similar bodies used by the Dolomite Products Company 
for handling rock from electric shovel to crusher. 


These bodies were designed and arc welded by the Genesee Bridge Company, Inc., 
Rochester, N. Y. ; 


The figures refer to the standard steel shapes used to make this body: 


1. 3%” Bottom Plate. 5. 4”x10.5 Ib. I-beam. 
2. 3%” Side Plate. 6. Ditto. 

3. 4x5x% Tee. 7. 4x4x¥ Angle. 

4. 4”x7.25 1b. Channel. 8. 2144x214, x % Angle. 


Page 46 


Metallic Arc Welding 


In this process the arc occurs be- 
tween the work to be welded and a 
metallic wire. Under the intense 
heat developed by the arc a small 
part of the work to be welded is 
brought to the melting point almost 
instantaneously. The other end of 
the arc, the tip of the metallic wire, 
is likewise melted and a globule of 
molten metal forms. This globule 
is then carried across the arc and de- 
posited in the molten seat waiting 
for it in the work. The globule is 
actually carried across the arc and 
not dropped as gravity does nothing 
more than assist this deposition of 
metal when the work is flat. The 
fact that this globule of molten 
metal will be deposited overhead 
against the force of gravity is proof 


Fig. 67 


Metallic Electrode Welding. The elec- 
trode in this case is a metal wire of small 
diameter and this wire gradually melts it- 
self away, furnishing metal for the weld. 


that the process is one of deposi- 
tion. It is this fact which permits 
the use of metallic arc welding in 
overhead welding which is im- 
possible by any other process. 


Carbon Arc Welding 

In carbon arc welding the arc is 
formed between the work and a 
carbon rod held in the electrode 
holder. The heat of the arc melts 
a small pool in the surface of the 
work to be welded. This pool is 
kept molten by playing the arc 
across it and extra metal is added 
by a filler rod to form the weld. 
Carbon arc welding is a puddling 
process, and is not applicable to 
vertical or overhead welding. Its 
greatest application is in automatic 
welding or in welding heavy sec- 
tions where much heat is required. 


Fig. 68 


Carbon Electrode Welding. The opera- 
tor holds the carbon electrode with the 
right hand and feeds the filling metal into 
the weld from a rod held in his left hand. 


Page 47 


Fig. 70 
All steel dump body for Ford truck, manufactured by The Galion Allsteel Body Co., 
Galion, Ohio. Arc welding has superseded riveting wherever a permanent joint 


is required. 


Page 48 


* 


The Simplicity of Arc Welding 


An arc welder usually represents 
an investment of less than $1000 
and takes up about 15 square feet 
of floor space. Any workman cap- 
able of learning to set up work on 
a lathe or milling machine can learn 
arc welding in a comparatively short 
time. 

The current used for arc welding 
is of a lower voltage than that used 
on a house lighting circuit and is en- 


Fig. 71 


Miscellaneous parts arc welded by The 
Link-Belt Co., Philadelphia, Pa. 


tirely safe in the hands of an ordi- 
narily skilled man. Adjustments or 
repairs which may be necessary can 
be made by an electrician. The 
equipment is simple in construction 
and in principle requires very little 
attention other than oiling. Com- 
plete data on various styles of arc 
welders and on the speed and cost 
of welding will be found in subse- 
quent chapters. 


Fig. 72 


Keystone Driller Co., Beaver Falls, Pa., — 
arc weld round and square tanks as well 
as other equipment for the oil industry. 


Page 49 


Fig. 73 


Air pipe completely arc welded by Littleford Bros., Cincinnati, Ohio. Other products 

arc welded by this company include: Jacketed pressure tanks, fuel oil tanks, under- 

ground storage tanks, air preheaters, gear guards, lathe pans, conductor piping hoppers, 
chutes and other power plant equipment. 


Fig. 74 


Portable conveyor manufactured by The Fairfield Engineering Company, Marion, O. 
The vertical members are arc welded to the axle, and arc welding is used on side 
_ Shields, gear covers and cross frame members. 


Page 50 


How Steel is Joined by Arc Welding 


In joining steel by arc welding 
the metal deposited by the metallic 
electrode, or added by the filler rod 
in the case of carbon arc welding, 
unites with the steel and forms a 
solid integral joint. 


The metal added to form the weld 
is of the same chemical composition 
as the steel parts to be welded. It 
has the physical characteristics of 
cast steel. 


While the tensile strength of cast 
steel is less than that of rolled steel, 
it is possible by depositing enough 
additional metal to build the 
strength of any joint up to the 
strength of the parts joined. A com- 
plete discussion of the strength of 
welded joints will be found in 

pages 111 to 121 inclusive. 


There are four different ways of 
joining steel plates by arc welding 
These are: 


1. The butt weld. 
2. The lap weld 

3. The fillet weld. 
4. The rivet weld. 


Two styles of butt weld are 


illustrated in figures 75 and 76. The 
edges of the two plates are butted 
together and the weld made by de- 
positing the welding metal along the 
edges. In metallic arc welding, 
when the thickness of the plates is 
greater than 10 gauge, it is desir- 
able to scarf or bevel the edges as 
shown. (No scarfing is necessary 
when carbon electrodes are used.) 
The plates may be double beveled 


or single beveled. This type of 
joint is the most economical from 
the point of saving material. 


A single lap weld and a double lap 
weld are illustrated in figures 77 
and 78. One piece is lapped over 
the other and the welded metal is 
deposited along the edges as shown. 
The double lap weld is used where 
maximum strength is required. 


The fillet weld is really a modi- 
fication of the butt weld. Figure 81 
shows how the metal is deposited to 
form the weld. This method of 
construction has a wide range of 
applications. It avoids the use of 


Crp ainnansilal Sag maa TS 


Fig. 75 
Butt Weld—Single bevel. 


RESTS COMERS nD, 


Fig. 76 
Butt Weld—Double bevel. 


Fig. 77 
Single Lap Weld. 


anna ea | 


Fig. 78 
Double Lap Weld. 


Page 51 


Fig. 79 
Until it was definitely proven that an arc-welded steel flask was superior in every 
way to a riveted steel flask, The Shanafelt Manufacturing Co., Canton, Ohio, pro- 
duced both. Now their entire output is arc welded. Shanafelt steel flasks are made 
in many sizes and styles to meet all requirements. 


Fig. 80 
These switch panels are all steel. Panels and brackets are arc welded. 


Page 52 : 


flange angles which are required in 
riveted construction. 

The rivet weld is used where it is 
not feasible to use a lap weld or a 
butt weld. Holes are drilled or 
punched through one of the pieces. 
This piece is placed against the piece 
to be fastened to it and the welding 
metal is deposited in the holes. A 
solid plug of steel which is com- 
pletely welded to both members is 
the result. This type of construc- 
tion is exceedingly useful when 
metal cannot easily be applied on the 
edges of the parts to be joined. 
This construction has many advan- 
tages over ordinary riveted construc- 
tion. The rivet weld will not loosen 
under a weaving strain because the 
welding metal is integral with the 
parts joined. Since holes are made 
in only one of the members there is 
no difficulty in registering. There- 
fore no laying-out or templates are 
required. Furthermore there are 


no protruding heads as in ordinary 
riveting. 


Fig. 81 
Fillet Weld. 


Fig. 82 
Rivet Weld. 


Fig. 83 
Truck body manufactured by the Truck Equipment Co., Buffalo. N. a 


Page 53 


LIVE COMEN 
Fig. 84 


Platform and racks for use in manufac- 

turing plants must be strong enough to 

withstand hard use and light enough to be 

transported easily. Here are three styles 

which meet these conditions. Arc-welded 
by Lewis Shepard, Boston, Mass. 


RIN TYPE PL. 


Fig. 85 
Arc welded skid grab for handling paper. One of many applications of arc welding 
made by The Cleveland Crane & Engineering Co., Wickliffe, Ohio, in the manufacture 
of material handling equipment. 


Page 54 


ADDENDA TO CHAPTER III 
Other Methods of Welding 


As a matter of interest a brief descrip- 
tion is given here of other methods of 
welding which have a more limited range 
in general manufacturing. Each method 
has its field but none of them can ap- 
proach arc welding in speed, economy; 
dependability, or all around utility. 


There are four other methods of weld- 
ing, differentiated chiefly by the method 
of heating the work. These are: 


1. Forge or fire welding. 

2. Thermit welding. 

3. Resistance welding. 

4. Oxy-acetylene or gas welding. 


Forge welding is the method of the 
blacksmith shop. The metal is heated in 
the forge and hammered on the anvil. 
Because of its cost and obvious slowness 
this method is not a process which can 
be used widely in production manu- 
facturing. For certain classes of work 
this process has been improved by the 
development of heating furnaces and 
power hammers. 
tions, however, is extremely narrow. In 
structural steel construction as used in 
building it is obviously out of the ques- 
tion to use forge welding. 


Thermit welding is essentially a cast- 
ing process. The heat is produced by 
the chemical combination of iron oxide 
and powdered aluminum. When this 
mixture is ignited it generates tremendous 
heat and releases molten metal which 
unites with the parts to be joined thus 
forming a weld. It is necessary to pro- 
vide moulds to confine the molten metal 


the same as in any casting process. © 


Thermit welding has a certain usefulness 
in the repair of heavy parts but because 
of the necessity for moulds and dams it 
is not practicable for production welding. 


In resistance welding the necessary 
heat is produced by an electric current. 
In this process the pieces to be welded 
are placed in contact and an electric 
current passed across the junction. Be- 


The range of applica- © 


cause of the imperfect contact the re- 
sistance to the passage of the electric 
current is high. The heat produced by 
this action causes the metal at the junc- 
tion to become plastic and when the de- 
sired plasticity. has been reached the 
pieces are forced together and a weld 
results. This process is used chiefly in 
spot welding of surfaces usually of 
rather light material. It has a limited 
application in general manufacturing. 

In oxy-acetylene or gas welding a 
flame produced by the burning of oxygen 
and acetelyne is played upon the surfaces 
to be joined and the extra metal is added 
to the junction by the melting of a filler 
rod of suitable composition. Gas weld- 
ing has a wide application in repair work 
where the amount of welding is not large. 
It is also used to a certain extent in 
general manufacturing. 

Notwithstanding the comparatively low 
first cost of equipment, the high operat- 
ing cost makes it less economical than 
arc welding for production work. 

It is very difficult to weld vertical 
seams or overhead seams because gas 
welding is a puddling process. That is, 
the molten metal forming the weld is in 
a small pool over which the flame is con- 
stantly played. Making a weld consists 
largely in causing this pool to move by 
melting metal away ahead of the pool 
and letting the metal cool behind it. 

A further disadvantage of gas welding 
is the fact that the heat is applied to the 
metal externally. The flame rebounds 
and spreads considerably away from the 
locality where the weld is to be made. 
This frequently causes warping of the 
parts unless elaborate precautions are 
taken which necessarily increase the 
cost. The cost of the heat used by this 
process is about three times as great as 
with the arc process and less than one- 
third is used in the weld—the rest is 
blown away by the action of the flame 
itself. 


Page 55 


Fig. 86 


Snow King, the rotary snow plow manufactured by the Imperial Machine Company, 
Minneapolis, Minn. Arc welding accounts for the sturdy strength of this machine. 


Fig. 87 


The cutting edge, stiffener braces and rotor blades are all arc welded. Notwithstanding 
the severe service which the rotor blades encounter, such as striking rocks and fence 
posts, there have been no failures of the welds. 


Page 56 


CHAPTER IV 
Arc Welding in General Manufacturing 


HE shop superintendent or the 

designer who does not know arc 
welding is probably losing money 
for his firm. He is authorizing 
drilling, punching, reaming, bolting 
and riveting where arc welding will 
do the work better and cheaper. He 
is using iron castings where arc- 
welded steel would be cheaper and 
stronger. 


The arc welder is a production 
tool. In modern manufacturing it 
is as fundamental as the lathe, the 
drill press or the milling machine. It 
is just as important for the up-to- 


date designer to know arc welding 
as it is for him to know the funda- 
mentals of forge shop practice or 
machining methods. 


Firms that, have been the first to 


redesign their products for arc weld- 
ing are reaping the profits which 
come from lowered costs. The wide 
range of products illustrated in this 
book barely indicate the possibilities 
of this process. New applications 
are being made daily and every new 
application means that some one has 
found a way to make his product 
better, or to make it at a lower cost. 


Fig. 88 


Well pumping rig redesigned for strength and economy. 


The left hand picture shows 


riveted construction with cast-iron pump housing. The right hand picture shows the 


same equipment built of arc-welded steel. 


Photographs by courtesy of American 


Crane Co., Friendship, N. Y. 
Page 57 


Fig. 89 


Use standard steel shapes. Many styles and sizes are carried in stock. 
Above are only a few of them. 


Page 58 


edestenitg for Arc Welding 


When the engineer comes to realize 
that welded joints are stronger than 
any other method of joining metals 
and at the same time the least ex- 
pensive he will have learned the 
most important step in redesigning 
for economy. 


The next important step is the 
realization that practically’ any part 
that can be made in cast-iron can be 


made up of standard steel shapes 


welded together. At first glance 
this seems almost unbelievable but a 
thorough analysis will prove the 
truth of this statement. Steel shapes 
are available in a wide variety of 
A few of these are 


reproduced in figure 89. It is some- 


styles and sizes. 


times necessary to bend or roll these 
standard shapes to produce the part 
required, but steel has such a large 
price advantage over cast iron that 
this can usually be done at a saving. 


Sheets Plates 


Castings or Forgings 
to Plates 


Tubes and Pipe 


Channels, Angles. 
Bars Ete. 


Angles 


Fig. 90 


Welding is the strongest method of joining steel parts and the least expensive. 


Page 59 


Fig. 91 


The Ljungstrom Air Preheater, manufactured by The Air Preheater Corporation, 

Wellsville, N. Y., is a remarkable example of equipment designed to be produced by 

arc welding. This preheater is built in various sizes up to 18 feet in diameter and 21 feet 

high. Casting the moving parts would make them too heavy to function properly to 

say nothing of the prohibitive cost. Riveting would be too expensive and would 

likewise increase the weight unnecessarily. Arc welding is the only method by which 
this equipment can be economically manufactured. 


Fig. 92 re Fig: 935 


The rotor of the Ljungstrom Air Pre- Upper and lower section of housing for 

heater. All joints are arc welded. No the Ljungstrom Air Preheater. Sections 

other method of making this rotor would are bolted to facilitate shipping. All per- 

give light weight, low cost and necessary manent joints are arc welded. 
strength. 


Page 60 


Replacing Castings by Arc-Welded Steel 


When redesigning a casting for arc 
welded steel : 


First. Study the casting and de- 
termine definitely just what its func- 
tion is in the machine and what re- 
quirements it must meet. When this 
is done it is a simple matter to decide 
whether or not a suggested change 
in form or shape is allowable. 


Second. Analyze the casting into 
its component parts and choose the 
standard steel shapes which will do 
the same job that the various parts 
of the casting are called upon to do. 
If the point of view is cultivated of 
looking at every casting as an 
assembly of parts rather than as a 
composite whole this analysis of 
shape comes naturally whenever a 
new casting presents itself. 


CAST IRON 


Third. 
all parts of a particular casting can 


It sometimes occurs that 


be replaced by standard structural 
steel except some detail which is 
necessarily of peculiar shape. In 
this event, the rolling or bending fix- 
ture will take care of a very large 
percentage of these cases by chang- 
ing the form of the standard steel 
shape to make it conform to the re- 
quirements of the design. The roll- 
ing of a standard angle into a cir- 
cular ring is an example of this. 


Fourth. 
some details which do not seem 


There may still occur 


susceptible to the rolling or bending 
(which 


are very rare) recourse must be 


processes. In such cases 


made to a cast or pressed steel part. 


ARC-WELDED STEEL 


Fig. 94 


The most intricate casting can be replaced by arc-welded steel. 


Page 61 


Fig. 95 


The Killefer Manufacturing Co., 
Los Angeles, Calif., manufac- 
ture a wide variety of road 
building and agricultural ma- 
chinery. They  state,—“‘Arc 
welding is used in so many 
places that it is impossible to 
give a complete list of our 
welding operations.” 


Arc welding enables The Euclid Crane and Hoist Company, Euclid, Ohio, to sell this 
efficient scraper at an extremely low price. It is built for rigid service. All perma- 
nent joints are arc welded. 


Page 62 


‘ 


Redesigning the Entire Product 


The range of products made from 
iron and steel is a vast one. To at- 
tempt to give detailed instructions 
on how to redesign every product 
for arc welding would be both pre- 
sumptuous and futile. A detailed 
description of the method of rede- 
signing a concrete mixer would not 
interest the builder of highway 


bridges—yet in both of these prod- » 
ucts arc welding can be utilized to 
advantage. Only the fundamental 
principles -of redesigning for arc 
welding fall within the scope of this 
book but it is believed that with a 
knowledge of these principles the 
designer will have no difficulty in 
applying them to his own product. 


Fig. 97 
There are two reasons why The Jaeger Machine Co., Columbus, O., use arc welding on 


this concrete mixer. One is to keep the cost down, because the market is highly 
competitive. The other is to give this mixer the husky strength to stand up under the 
service expected of Jaeger equipment. 


Page 63 


___ Container. & Cover 


Ja 
Pfu : 


‘A 


SN 
wl 
SS 


oe; 


,/ 
“Le. 


MOL 


— 


| 
ha 


A<—ss 


Ue 
ay) 
O 
n 
Z. 
p 


(ore ae Container 
| LS 2 ( 


Cover 


| Container 


jj Cover 


4 
— 


SS 


7 


Yh 11 1h Y 
ce 


Base 


Base Coveiner 
, Fig. 98 


The structural parts of every machine may be classed as either bases, 
covers or containers. 


Page 64 


Bases, Covers and Containers 


Notwithstanding the diversity of 
products manufactured from iron 
and steel, there are still some char- 
acteristics which are common to all. 
It will be found upon careful 
analysis that every structural part of 
any, machine, structure, or piece of 
equipment can be classified in one 
or more of these three classifications 
—bases, covers, and containers. It 
may be a new conception to think of 
all structural machine parts as being 
so simply classified, but a little 
thought will show that this is true. 
Some parts may fall in both classi- 
fications. A worm gear housing, 
for instance, may be classed both as 
a base and as a container if it serves 
to support, as well as enclose, the 
moving parts. This, however, does 


not make the classification any less 


Fig. 100 


valuable for the purpose of this 
discussion. 


Figure 98 shows two widely dif- 
ferent pieces of equipment with the 
various parts labeled in accordance 
with this classification. 


In this Worm Gear Housing the Base 
is also a container. 


Manufacturers of fans and blowers have been among the first to redesign for arc 
welding. Steel has replaced cast iron throughout in the construction of these models 
built by the Robinson Ventilating Co., Pittsburgh, Pa. 


Page 65 


Fig. 101 
Backfiller manufactured by The 
Killefer Manufacturing Com- 
pany, Los Angeles, Calif. The 
rocker arms on this machine are 
made by arc welding extra- 
heavy pipe to a steel casting. 
This company arc welds all 
kinds of agricultural machinery. 


Any Base Can Be Built of Arc Welded Steel 


The term base, as used here, is 
intended to embrace every part 
whose chief function is to support. 
It includes: 

Brackets, Beds, Legs. 

Superstructures. 

Outboard bearings, Pedestals. 

Arms, Goosenecks, End Brackets. 

Bearing boxes, etc. 

At present, by far the majority 
of bases are made of cast iron. 


Riveted steel is also used, but this 
discussion has to do chiefly with re- 
designing cast iron bases on the 
assumption that where riveted steel 


is now used the application of arc 
welding is obvious. 

Fortunately, redesigning for arc 
welding is a comparatively simple 
matter. It is much less difficult to 
design a machine base of arc welded 
steel than to design the same base in 


cast iron. 

It is not necessary to allow for 
casting shrinkage, draft on patterns, 
cores or fillets. The designer works 
directly for the ultimate result, un- 
hampered by limitations of the cast- 
ing process which make it impossible 
to cast the most efficient sections. 


Fig. 103 
A fine example of light, strong and economical construction for machinery bases. 
This machine and many others manufactured by The Parks Ball Bearing Machine 
Company, Cincinnati, O., are arc welded throughout. 


Page 67 


Fig. 104 
Assembling the 300-ton press brake illustrated below. This picture gives an idea of 
the size of this huge machine. Steel is superseding cast iron in the manufacture of 
machine tools where great strength is required. 


Fig. 105 


300-Ton Press Brake manufactured by the Cincinnati Shaper Co., Cincinnati, Ohio. 
This machine is 11 feet 9 inches high. Note how rolled steel has replaced cast iron. 
Arc welding is employed to give this machine its extreme rigidity. 


Page 68 


First, analyze the purpose of 
every part of the base. Then de- 
termine the stress to which every 
part is subjected. It is usually a 
simple matter to determine whether 
a member is in tension or compres- 
sion. If it is subjected to both 
stresses, the designer can usually 
tell which stress is the more im- 
portant. He can also determine 
with sufficient accuracy, the amount 
of the stress, which, of course, 
governs the size of the members. 
This is fundamental to all designs, 
whether the base is to be made of 
cast iron, riveted steel or arc welded 
steel. 


The next step is simply to select 
the standard steel shapes which will 
best meet the above conditions. Join 
the standard steel shapes by arc 
welding with the assurance that the 
joints will be as strong as the mem- 
bers joined. The entire base will 
be an integral piece of steel—lighter 
in weight, stronger and less expen- 
Since steel is 
stronger than cast iron the various 


sive to manufacture. 


parts of the base can be made 
smaller. This may change the ap- 


pearance of the base somewhat but 
will in no way interfere with its 
utility. 


Ge Tensor 


Tensor 
Compression 
Fig. 106 
Every structural part of any machine is subjected to either tension or compression or 
bending. 


Page 69 


Fig. 107 


Special-purpose trucks of all descriptions can be made quickly and cheaply by arc 
welding. Here is one that was built to facilitate unloading steel shapes. 


Fig. 108 


The frames of these dryer cars are made of 3”x3”x!4” steel angles bent around a 
form and arc welded, making a solid, rigid one-piece frame. These cars are manu- 
factured by The Hadfield-Penfield Steel Company, Bucyrus, Ohio. 


, Fig. 110 


Base for direct connected motor driven machine. 


In this manual are illustrated 
many different styles of bases which 
were built on this principle. It is 
not feasible to describe them all and 
in most cases the pictures them- 
selves are self explanatory. 


In figure 110 is a simple example. 
This type of base is suitable for any 
direct connected motor-driven unit 


‘such as a pump, a crusher, a gener- 


ator, elevator engine, etc. As the 
illustration shows it is made entirely 
from standard steel shapes. 


Pig uit 


Elevator base redesigned for arc welding by the Houghton Elevator Company, 


Toledo, Ohio. 


Sean rie ek eee 
ETS BES BO 2 a ir 


The cost figures are convincing. 


Weight Cost 
fl Ay ee apg A P Se A 184 Ibs. $11.04 
BS strength Se by ye ues see ae, 109 lbs. 5.45 


Fig. 112 


Arc-welded bases need not be awkward. 

While the bases for these machines look 

different from the traditional cast-iron 

bases, they are graceful and workmanlike. 

They are also cheaper than cast iron and 
stronger. 


Page 72 


Typical Base for Floor Grinder 


Another example is a base for a 
machine such as a floor grinder, a 
polishing wheel or an arbor press. 
The machine base in this case is 
simply a support to bring the work- 
ing parts to a convenient height. 
Of course, the base must be reason- 
ably rigid to avoid undue vibration. 

To make a base of this nature of 
welded steel, a standard I-beam 
serves as the column support. Two 


flat plates welded on the foot of the 
I-beam provide the large floor bear- 
ing. Welded braces made from steel 
plates give the necessary stiffness 
and another flat plate forms the bed 
for the working parts. The entire 
base can be built before the pattern 
shop could lay out the core box for 
a cast iron base and at a fraction 
of the cost. 


Fig. 113 : 
The welded steel base is more rigid than the cast iron base costs less and requires 
practically no machining. 


Page 73 


Trev CS | nay - wea 9+ Ros 


Fig. 114 
Boring mill bases have always been made of cast iron. Below is a similar base 
of arc-welded steel. 


An All Steel Lathe 


Examples might be multiplied, 
but the truth is apparent that the 
sole purpose of any base is to sup- 
port the moving parts, whether the 
machine is a grinder, a concrete 
mixer, or a portable coal loader. 
The best base is the one which has 
the necessary strength and rigidity 
and which can be built at the lowest 
cost. 


Let us consider another example 
of a machine which has heretofore 
been made of cast iron, namely an 
A lathe con- 
sists fundamentally of four parts—a 


ordinary engine lathe. 


bed, a headstock carrying the driv- 
ing mechanism, a carriage which 
slides along the ways on the bed, and 
a tailstock. The purpose of the bed 
is simply to support the moving 
parts and keep them in alignment. 
It is extremely important that the 
bed be sufficiently rigid so that it 
will not deflect under the pressure 
exerted against the lathe tool. In 
other words, the greatest stress is a 
bending stress. 


Since cast iron is weak in flexure, 
lathe beds are built with a very deep 
web to provide the necessary rigid- 
ity. 
tern from the sand in the foundry, 


In order to draw the bed pat- 


the shape of the casting must be 
made radically different from the 
shape which would withstand the 
greatest bending stress. This is one 


of the limitations of the casting 
process. 


Now suppose this lathe bed to be 
made of welded steel. Since it is 
called upon to withstand a bending 
stress, the steel section best suited 
for this purpose is chosen, that is, 
the standard I-beam. 


Instead of the heavy cast iron 
base, two I-beams would be solidly 
joined together by arc welded cross 
braces. 


The legs would be made of either 
I-beams, standard channels or angles 
depending on the design. 


Hardened steel ways screwed to — 
the tops of the I-beams would re- 
place the cast iron ways, providing 
a simple means for renewal when 
badly worn. 


Because of the greater strength 
of steel and because the most effi- 
cient sections can be used, a welded 
steel lathe would be stronger, lighter 
and cheaper than a cast iron lathe. 
Obviously it would not look the 
same. Its first appearance would 
doubtless cause smiles from users 
accustomed to the flowing curves 
and deep fillets of cast iron construc- 
tion. 


Fillets and curves, however, are 
but evidences of the limitations of 
cast iron and it will be only a short 
time before steel bases are accepted 
as standard on most machine tools. 


Page 75 


Fig. 116 


Gear Guards of every size and description are arc welded by the Link-Belt Company, 
Philadelphia, Pa. 


Page 76 


Make All Covers of Arc Welded Steel 


The term covers, in this classifica- 
tion, is intended to include: 

Gear guards. 

Doors. 

Pulley housings. 

Dust covers. 

Lids for ‘oil wells, etc. 

The purpose of covers on any 
machine is either to protect the in- 
ternal mechanism from damage 
from the outside or to shield the 
moving parts so that they them- 


The gears on these overhead crane trolleys are enclosed in guards of arc-welded steel. 


selves will not be a source of dan- 
ger. Usually covers are not sub- 
jected to any considerable stress, 
and consequently the lightest cover 
is the best cover provided it has the 
requisite stiffness. 

Gear guards probably are the 
widest used form of covers. The 
former method of making these was 
either by casting or by riveting 
steel. Cast gear guards have all the 
disadvantages of any cast-iron prod- 


This is one of the many applications made by the Whiting Corp., Harvey, III. 


_ Fig. 117 
Pager ey 


OCONEE 


Fig. 118 


Arc welding is used extensively by the Butler Bin Co., of Waukesha, Wis., in the 
manufacture of their batch measuring hoppers and other products. 


Fig. 119 
Conveyor buckets arc-welded by The Link-Belt Company, Philadelphia, Pa. 


Page 78 


uct which include high cost and un- 
necessary weight. Riveted gear 
guards, while utilizing less expen- 
sive steel, require flanging or flange 
angles, so that the cost to manu- 
facture is often higher than that of 
a casting. Furthermore, the rivets 
have'a tendency to work loose under 
the constant vibration to which gear 
guards are subjected. 

The construction of arc-welded 
gear guards is simplicity itself. 
Sheet or plate is cut to the proper 
shape and the edges welded so that 
the entire part is an integral piece of 
steel. Gear guards of this nature 
may be made dust tight and oil tight 
and the cost is a fraction of that for 
other methods. 

Covers other than gear guards 
can be made in the same manner. 
Use standard steel sheet or plate 


Laundry Machinery Co., 
Mass. 


The cylinder, gear guards and many 
other parts of the Henrici washer are 
arc welded. This is one of large num- 
bers of models built by the Henrici 
Boston, 


form if necessary and weld all 
joints. 


An example of a cover known to 
everyone is a door such as is used 
on a milling machine and very fre- 
quently on other machine tools. 
This door carries no part of the load 
on the machine, and is only subject 
to breakage through being struck. 
However, because cast iron is ex- 
tremely brittle in thin sections, doors 
are cast in sections many times ° 
heavier than would be required if 
steel were substituted. 


Doors of this nature can be easily 
made from flat stock stiffened where 
necessary by welding on ribs or 
angles. Hinges and knobs can like- 
wise be welded on and the cost 
would be less than for any other 
style of construction. 


Page 79 


OUTSIDE WRAPPER SHEET 


000000000 
oe OO0000000 
60000000000 


O 
99000000000 
00000000000 
00000000000 


00000000000 
00000000000 
000000000 
0000000 


REAR 
TUBE SHEET 


FIRE DOOR 
RING 


FRONT 
TUBE SHEET 


0000000000 
00000000000 
000000000 

0000000 


FIREBOX REAR 
HEADER AND 
TUBE SHEET 


FIREBOX 
FRONT HEADER 


= WRAPPER SHEET 
Fig. 121 


All seams of this heating boiler are arc welded. Note the simplicity of construction. 
Only seven steel plates are used. The Heggie-Simplex Co., Joliet, Ill., manufacturers 
of this boiler, arc-welded all of their various models. 


Page 80 


Arc Weld All Containers 


The classification containers is 
extremely broad and includes: 

Tanks of every description. 

Boilers. 

Hoppers.. 

Drums, 

Bins. 

Chutes. 

Mixing chambers. 

Tumbling barrels. 

Vats. 

Revolving driers. 

Dump cars. 

Clamshell buckets. 

Annealing pots, etc. 

Tanks will be considered first be- 
cause their use is more general 
than any of the other items in this 
classification. 


The first requisite of a tank is that 
it be tight. It must also have 
sufficient strength to withstand the 
internal pressure to which it may be 
subjected. In pressure tanks the 
plates and joints are in tension. In 
riveted construction, which was 
formerly the only method of mak- 
ing pressure tanks, the strength in 
tension of a riveted joint is always 
less than the strength of the plates 
joined. ‘This is because the plates 
are weakened at the joint by the 
rivet holes. To obtain the necessary 
strength it is therefore necessary to 
provide: for this weakness at the 
joints. Since the efficiency of the 
usual riveted joint varies from 45% 


Fig. 122 


Arc-welding is the approved method of making tank trucks for transporting in- 
flammable liquids. This one was built by the A. F. Robinson Boiler Works, Boston, 


Mass. 


There are no rivets to work loose and start leaks. 


Page 81 


Fig. 123 


Arc-welded water tanks are superseding riveted tanks because they do not require 
periodic recaulking, This one was built by The Leitelt Iron Work, Grand Rapids, Mich. | 


Page 82 


to 75%, the increase in the thickness 
of the plates to provide for this is 
considerable and represents a large 
part of the cost of any tank. 

In arc-welded construction the 
joints can be made as strong as the 
plates joined. It is not necessary to 
make the plates thicker throughout 
their length to provide for the re- 
quisite strength at the joint. The 
plates are no more apt to fail there 
than at any other point. 

Here, then, is one great saving by 
using arc welding in place of rivet- 
ing. Furthermore, the actual cost 


Fig. 124 


This Bousman Still is used for reclaiming 
gasoline and other solvents used for dry 


cleaning. The Bousman Manufacturing 

Co., Inc., Grand Rapids, Mich., have 

found that arc-welded stills cost less and 
last longer than riveted stills. 


of making the welded joint is less 
than that for making a riveted joint. 

In tank work there is still another 
advantage. In riveted tanks the 
method of making tight joints is by 
peening the metal along the edge of 
the plates into the joint by means 
of a caulking tool. This method is 
a makeshift at best and is also ex- 
pensive. It is frequently necessary 
to recaulk after the tank has been 
in service a short time. Arc welded 
tanks are tight because the plates 
are solidly joined, making the tank 
actually a single piece of steel. In 
addition, a welded tank resists cor- 
rosion better than a riveted tank, 
and avoids leaks around rusted 
rivets. 


Fig. 125 
No one wants a leaky gasoline or oil tank. 
That’s why the S. F. Bowser & Co., Inc., 
Fort Wayne, Ind., arc welds the seams of 
this tank and many other styles of dis- 


pensing tanks. An arc-welded seam for- 
ever eliminates caulking. 


Page 83 


Fig. 126 


Locomotive tender built by the Baldwin Locomotive Works, Philadelphia, Pa. 
Arc-welding has replaced riveting throughout. An arc-welded joint withstands vibra- 
tion better than.a riveted joint. 


Fig. 127 


The interior of a large fuel oil storage tank built in accordance with the New York 

City Building Code. This tank is stayed with 15%” steel rods on 24” centers. Stays 

and plates are completely arc welded. The Lancaster Iron Works, Lancaster, Pa., 

has made these tanks for the Equitable Life Building, Federal Reserve Bank, Waldorf 
Astoria Hotel, Astor Hotel, Belmont Hotel and others. 


Page 84 


In making tanks by arc welding, 
the plates may be joined by butt 
. welding, by single lap welding or by 
double lap welding. The butt weld 
has the advantage of great strength 
and also saves material. The cost 
of fitting and scarfing the plates, 
however, often offsets the saving in 
material. Where the tank is used 
for storage purposes and is not sub- 
jected to high pressure, the single 
lap welded joint may be used. For 
pressure tanks the double lap weld 
is recommended as this joint is as 
strong as the plates used. 


Various methods of welding the 
heads in tanks are illustrated in 


figure 138. Very large tanks may 
be strengthened by stay rods, welded 
at all intersections as illustrated in 
figure 127, 

Containers other than tanks can 
also be made by arc welding cheaper 
than by riveting or casting. Ex- 
amples, including conveyor buckets, 
concrete mixing drums, compensator 
housings, and many others, are il- 
lustrated in this manual. The de- 
signer will have no difficulty in see- 
ing how arc welding is utilized in 
making these and will doubtless find 
many suggestions which he can 
apply to his own problems. 


Fig. 128 
The oil pan on this turret lathe, manufactured by The Warner & Swasey Co., 
Cleveland, Ohio, is made of arc-welded steel. 


Page 85 


but to make this part by rivet- 

ing 8 flat pieces plus 12 pieces 

of angle are required. A total 

of 20 pieces to do the work of 

8. To say nothing about the 

cost of punching rivet holes 
and driving rivets. 


Page 86 


Arc welding saves material. To make 
this part by arc welding—8 pieces of flat 
stock are required, 


Fig.0129 


Arc-Welded Wheels 


Arc welding is used extensively in 
the manufacture of wheels for vari- 
ous purposes. . 

One example is the wheel for a 
shop truck, illustrated in figure 130. 
Like many similar wheels this wheel 
was formerly made of cast iron. 
The manner in which steel was sub- 
stituted is clearly shown in the il- 


lustration. The rim is formed by 


rolling a standard T-bar into a circle 


The hub 


is made from a short length of 


and welding the junction. 


standard pipe and the spokes are flat 
bar stock. All parts are welded and 


the result is an all-steel wheel, 


stronger than the cast iron wheel 
and weighing but one-half as much. 
The cost of the cast iron wheel was 


$1.85 each and the cost’ of the 
welded steel wheel $.68—a saving 
of more than sixty percent. 


Fig. 130 


WHEEL FOR SHOP TRUCK 


ARC-WELDED STEEL, WT. 12.5 LBS. 


Cost of rolled steel________________ $ .35 
Pea UaTMCOSt=. ee eee ok 33 
ipraieecontas.- = 2... et $ .68 


CAST IRON, WT. 25 LBS. 


Cost of rough casting________-____-_ $1.75 
Danorecostie t= oe oe ee ce .10 
rrotalincosts. cee $1.85 


The arc-welded wheel is not only cheaper to make but weighs one-half as much as 
the cast iron wheel. 


Page 8&7 


Fig. 131 


There is not a single bolt or rivet in this 114-ton coal bucket built by the Godfrey 
Conveyor Company, Elkhart, Indiana. It is arc-welded throughout for strength. 


Page 88 


Fig. 132 


Eighteen foot band wheel built by the Oil Well Supply Co., Oil City, Pa. By are- 

welding the T-iron stiffener to the rim, 176 rivets were eliminated. In addition to 

reducing the cost, arc-welding made a better product. The smooth outside face of the 
wheel means longer life to the driving belt. 


Large hand wheels such as are 
used extensively on road building 
machinery are now made by arc 
welding from standard pipe of 
various sizes. The rim of the wheel 
in figure 133 is made by rolling up a 
circle of 14%” pipe. The spokes 
are of pipe of a smaller diameter 
weldéd to the hub. One large 
manufacturer reports that he keeps 
two arc welders constantly busy 
making hand wheels of this nature. 


Fig. 133 


Hand wheel made of 114” pipe with 34” 

spokes. Arc welded at all joints. Photo- 

graph by courtesy of Killefer Mfg. Co., 
Los Angeles, Calif. 


Page 89 


Se oe rn 


Fig. 134 Fig. 135 
Single Lap Weld. Suitable for thin sec- Double Lap Weld. This joint can be 
tions or where great strength is not re- made as strong as the members joined. 
quired. Note saving in material over double lap 
riveted joint. 
Fig. 136 
Butt Weld. This is a 100% joint. The amt 
edges of the plates should be beveled as Fig. 137 
shown. Double riveted joints. 


B C 


Fig. 138 


Three methods of welding flanged heads in-cylindrical tanks. Method C is the best 
practice where maximum strength is required. 


ME LLL 
YUH /000 


Z 
y 
Y 
Y 
j 
Yj 
Z 


GUSSET LETUL 


Fig. 139 Fig. 140 


Method of welding brace in place of 


rctags Welded corner stiffeners. 
riveting. 


Page 90 


Typical Welds and Short Cuts 


Too much emphasis cannot be 
placed on the economy of using 
standard parts in arc-welded con- 
In addition to rolled 
steel shapes,—standard pipe and 


struction. 


pipe fittings, standard hinges, stand- 
ard bolts and nuts and similar parts 
can often be used to take the place 
of special castings or forgings. 

The drawings on pages 92 and 
94 show typical details of arc welded 
construction making use of stand- 
ard parts. These drawings merit 
study. To appreciate the economy 
of these construction details, it is 
necessary to visualize the procedure 
required to get the same results by 
some other method. 

Suppose, for instance, a single 
T-bolt were required. This T-bolt 


could be hand forged, or it could 
be cast of malleable iron or steel. 
Any one of these methods would 
require much more time and would 
be far more expensive than arc 
welding. A round steel bar welded 
to a standard bolt solves the prob- 
lem. 

As another example, suppose that 
it were desired to fasten a piece of 
pipe to a channel beam. If a strong, 
rigid joint were required, it would 
be necessary to make a _ special 
clamp, either cast or forged, to hold 
the pipe. This clamp would have to 
be bolted or riveted to the channel 
beam which would mean drilling 
four holes in the clamp and in the 
beam. Then would come the actual 


assembly. 


Fig. 141 


Machine parts manufactured by The Jaeger, Machine Co., Columbus, O. Can any 
designer think of a more economical method of making these parts? 


Page 91 


 4))\ AMDT, 
P 


CSTE L(t LCL SLD oe 


Fig. 142 
Typical welds and short cuts. vid 


Page 92 . 


By arc welding the procedure is 
much simpler. The pipe is placed in 
position and molten steel deposited 
along the edges, making pipe and 
beam an integral part. The entire 
job would be finished in less time 
than it would take a draftsman to 
make a drawing of the clamp. 


Some of the sketches reproduced 
here are actual details of equipment 
in regular production, others are 
suggestions only. The only limit to 
the use of standard parts is the in- 
genuity of the designer. 


Another important feature of arc 
welding is the possibility of build- 
ing up pads, lugs and bosses. Where 
such a raised projection is necessary 
it can be made either by welding on 
a small piece of steel of the proper 
shape or by depositing metal from 
the electrode and actually building 
up a solid homogeneous pad. 


Fig. 143 


Pads and bosses can be built up by de- 

positing metal. The illustration shows a 

cross section of such a pad. Frequent 

examples of this practice are illustrated 
in this manual. 


Fig. 144 


Standard products can be used for special purposes when the designer possesses 


ingenuity and an arc welder. 


Here are four money saving examples used on products 


manufactured by The Jaeger Machine Co., Columbus, O. 
Page 93 


Fig. 145 
Typical welds and short cuts. 


Page 94 


Fig. 146 


Arc welding is now used by most manufacturers of tank trucks because an arc welded 
seam remains permanently tight. The Heil Co., Milwaukee, Wis., manufacturers of 
all kinds of tanks, were pioneers in the adoption of arc-welding. 


Truck bodies of every description are arc welded by the Truck Equipment Co., 
Buffalo, N. Y. Welding makes every plate and every brace a single integral piece. 


Page 95 


Fig. 148 


The Giant Slide at Riverview Park, Detroit, Mich., affords pleasure to thousands of 
persons each season. Their safety depends on arc-welded construction. 


Page 96 


ae 


ohige 


Arc Welded Design for Structures 


The use of arc welding for join- 
ing the structural steel framework 
for buildings and bridges is an ac- 
complished fact. A few of the 
structures made by arc welding were 
mentioned in an earlier section of 
this manual. The reason for using 
arc welding instead of riveting was 
solely because welding was better 
and more economical. It is entirely 
possible to arc-weld the framework 
for the tallest skyscraper, and 
eventually arc welding will largely 
replace riveting in this field. 

One of the largest manufacturers 
of fabricated steel has carried out 
extensive experiments on arc weld- 
ing. Their experiments have con- 
vinced them of the entire reliability 
of arc welding and also of the sav- 


ings possible by this method. The 
photographs reproduced here show- 
ing typical welded connections were 
taken from actual members used in 
construction work by this company. 


The details of arc welded designs 
are very little different from the de- 
tails of riveted designs. 


Figure 149 shows the main girder 
of a crane runway. This girder 
consists of a web plate, two angles 
on the bottom flange, and two an- 
gles and a cover plate on the top 
flange. The illustration clearly 
shows the method of welding a con- 
tinuous bead for a distance of 30 
inches from each end of the girder, 
and tack welding the intermediate 
distance. 


Fig. 149 


‘Main girder of runway for 100-foot span overhead traveling crane. 


Page 97 


Fig. 150 


Roof trusses of arc-welded steel are made for any span from 40 to 60 feet by the 
Massillon Steel Joist Co., Canton, O. 


Fig. 151 


Arc-welding made the Massillon Bar Joist possible. The design of this joist permits 
running pipes and conduits in any direction. There is the further advantage of light 
weight. Manufactured by The Massillon Steel Joist Co., Canton, Ohio. 


Page 98 


Fig. 153 


End view of plate 
and angle girder. 
Bars instead of an- 
gles are used for 
web braces. 


Figure 153 shows an end view of this girder. It will 

be noted that bars instead of angles were used for the 
web braces. This is possible because of the great 
strength of the fillet welds. 
_ Figure 154 shows a plate welded by a fillet onto an I- 
beam. The strength of this con- 
struction was questioned by one of 
the men in the erection shop and it 
was decided to make a real test. 
One man with a twelve pound sledge 
struck the plate 16 times on one side 
and 30 times on the other side with- 
out doing more than bending the 
plate. A battering ram, weighing 
587 pounds, was then suspended 
from the crane hook and after 46 
blows were struck the weld showed 
no failure. 


Fig. 152 Fig. 154 


Column for supporting crane runway Forty-six blows with a 12 pound sledge 
for 100-foot span crane. made no impression on this weld. 


Page 99 


Fig. 155 


The Diamond Hardware Mfg. Co., Pittsburgh, Pa., are weld steel roof trusses for 
small garages, warehouses and factories. These were formerly riveted, but arc weld- 
ing was found faster and less expensive. 2 


Fig. 156 


Page 100 


—sI*. 


| Fig. 158 

Figure 157 shows the method 
employed for welding a lintel used 
in a brick and steel building in Can- 
ton, Ohio. This carries a cover 
plate for the brick wall and also a 
shelf angle to support the floor 
joists. The tack welds are about 
four inches long. 


Figure 158 shows the method of 
welding end-connection angles, and 


seat angle construction is shown in 
figure 159. 


Page Ior 


Fig. 157 


Fig. 159 


Fig. 160 


Template for drilling machine base. The template as well as the product is 
arc welded. 


Fig. 161 
Jigs and fixtures arc welded by The Jaeger Machine Company, Columbus, Ohio. 


Page 102 


Fig. 162 


Punches and strippers made by arc welding. This illustration deserves close study. 


Arc Welding in the Tool Room 


Manufacturers have long been 
accustomed to high costs on special 
tools such as punches and dies and 
on jigs and fixtures. It is to be ex- 
pected that where only one or two 
similar tools are made, that the cost 
will be considerable. However, arc 
welding will reduce these costs. 

The toolmaker who knows arc 
welding is in a position to produce 
special tools more quickly and more 
economically. Figure 162 shows 
several punches and strippers made 
by arc welding. Steel plate replaces 
castings, eliminating pattern ex- 
pense. The cost of machine work 


is reduced by welding on projec- 
tions and lugs instead of machin- 


ing these parts from solid steel. 

Arc welding changes the entire 
conception of machine shop practice 
because now it is possible to add 
metal as well as remove it. The 
metal added is as homogeneous as 
rolled steel itself. At last the much 
sought for “adding on tool’ is here. 

Figures 161 and 163 show ma- 
chining jigs made by arc welding. 
Patterns are entirely eliminated. 
Think of the saving in time to pro- 
duce these jigs! Standard steel 
sections are used. The toolmaker 
puts them together. He does not 
wait for the patternmaker or the 
foundryman, but builds direct from 
his own sketches. 


Fig. 163 


Jigs and fixtures made by arc welding. 


Page 103 


Fig. 165 


Steel replaces cast iron in the Robinson 

Furnace made by The A. H. Robinson 

Co., Cleveland, Ohio. All seams are arc 
dA, aly welded. 

Fig. 164. Dirt and gas cannot escape ; 

through walls of arc-welded steel. This 


seamless furnace is made by The Water- 
man-Waterbury Co., Minneapolis, Minn. 


A 


Fig. 167 
; Arc welding is used to give added stiff- 
Fig. 166 ness to the American All Pressed Steel 
The Foamite mixing chamber for dis- Shafting Hanger, made by American Pul- 
charging Firefoam is built of arc-welded ley Co., Philadelphia. Steel hangers 
steel. This equipment is manufactured ‘ weigh about half as much as cast iron 
by Foamite-Childs Corp., Utica, N. Y. hangers. 


Page 104 


ved 
Pepe ep! 


There Is Real Selling Value in Being Different 


In redesigning don’t try to copy 
the appearance of the old design— 
the new design, if successfully en- 
gineered, will be sufficiently better 
and less expensive to overcome any 
sentimental attachment which tradi- 
tion-bound customers may have for 
bulky, massive, cast iron structures. 


There is a real selling value in 
being different, particularly when 
your product costs Jess to produce 
than your competitor’s. Freight is 
often a bar to good markets, and 
every pound that you can cut off of 


the weight of your product repre- 
sents money saved in transportation 
costs, whether you sell your product 
f. o. b. factory, or at your custom- 
ers door. Weight saved means 
money saved all along the line and 
on a cents-per-pound basis you will 
more than have the edge on cast 
iron competitors. 


Aim to design something which 
will do the work in the best possible 
way and take advantage at the same 
time of the strength, low cost and 
lightness of steel. 


Fig. 168 


Dube Water Heater and Garbage Burner built by Grand Crossing Boiler Works, 


Chicago, III. 


Note how the water tank is supported on a base made of standard pipe 
arc welded at the joints. The tank is also arc welded. 


Page 105 


Fig. 169 


Arc-welded barrel and drum racks built by Lewis Shepard Co., Boston, Mass. These 
racks are built of channel sections and combine great strength with light weight. 


Fig. 170 
Cradle for supporting tank on motor truck. Built by The Heil Co., Milwaukee, Wis. 


Page 106 


The Arc Welder in Maintenance Work 


The master mechanic or mill- 
wright will find many uses for arc 
welding. In erecting countershaft- 
ing or in mounting motors for in- 
dividual drive machines, supports of 
SrGuciittamecteel can be erected 
quickly and at low cost. 


Figure 171 shows a superstruc- 
ture for carrying the shafting for a 
cylindrical grinder. Light standard 
angles are used and all joints are arc 
welded. Notice the manner in 
which the I-beam for carrying the 
chain fall block is supported. 


Fig. 171 


Countershafting support for cylindrical grinders. Note the method of supporting 
I-beam for chain fall block. 


Page 107 


Fig. 172 


The truck for this portable unloader, built by The Burch Plow Works Co., Crestline, 

O., is arc welded for strength and rigidity. There are countless other machines now 

riveted or bolted where arc welding will add'‘to the strength and at the same time 
reduce the cost to manufacturers. 


Fig. 173 
The base of this self-contained refrigerating unit is made of arc welded steel. Photo- 
graph by courtesy of Baker Ice Machine Co., Inc., Omaha, Nebraska. 


Page 108 


Twelve Points to Remember in Redesigning 


1. The I-beam is the stiffest 
structural shape for its weight that 
can be designed. Use it for col- 
umns, or for transverse members to 
resist compression or bending. 


Z. The angle is strong in both 
compression or bending, and has the 
advantage of lending itself readily 
to arc welding. 


3. Welds should be put out of 
sight to eliminate finishing. 


4. Do not go to a special shape 
unless absolutely necessary, special 
shapes often mean costly delays. 
There is usually a way out. if the 
problem is studied thoroughly. 


5. Don’t feel that it is necessary 
to make the entire structure of rolled 
steel. Use castings, forgings or 
stampings where they are more eco- 
nomical. Arc welding is a new tool, 
not a fad. 


6. A lap weld may save many 
times the cost of making a butt weld 
by facilitating assembly and by the 
elimination of accurate fitting. 


or heavy plate. 


Fig. 174 
‘Arc welding is the most economical method of joining metals whether it is thin sheet 


7. Chamfering the edges may be, 
but is not usually, necessary. 


8. Use tack weld for assembly and 
after the structure is assembled, 
completely weld up the structure. 
Surprising economies are effected in 
this way. 


9. Use carbon electrode welding 
when the section is heavy and easy 
to get at, as it is faster and more 
economical. 


10. Don’t expect that you can re- 
design all of your apparatus at once. 
Speed is necessary, but speed and 
ideas do not always go together and 
ideas are more important. 


11. Don’t forget that the product 
you are now making will eventually 
be made by arc welding. The man 
who gets the answer first will be the 
leader and will reap the rewards of 
the leader. 


12 .otr engineering department 
must be “welding minded.” Weld- 
ing is a more useful tool to you than 
your drawing instruments. 


These parts are manufactured by The Jaeger Machine Company, 


Columbus, Ohio. 
Page 109 


Fig. 175 


Arc-welded reinforcing for concrete bank vaults. When this rein- 
forcing is installed every joint is welded, making an integral barrier 
of steel concrete reinforcement. Vaults of this construction defy 
fires, earthquakes and organized attacks of mobs. This is one of the 
applications of arc-welding made by the 
Massillon Steel Joist Company, Canton, Ohio. 


Fig. 176 
Lewis-Shepard jacklifts are noted for their sturdy construction. Arc welding helps to 
; maintain their reputation. . 


Page r10o 


CHAPTER V 
Strength of Arc Welded Joints 


T has frequently been stated in 

this manual that arc welding is 
the strongest method of joining 
steel parts. To those who have 
heretofore thought of welding as a 
sort of patching process, this state- 
ment may come as a surprise. It is, 
however, a literal fact that 100% 
joints are regularly made by arc 
welding, and the following discus- 
sion will show how this is possible. 


Strength of Butt Welds 

Let us consider, first, the butt 
weld. This style of joint is used 
chiefly where the parts are in ten- 
sion. Since the metal comprising 
the weld has the properties of cast 
steel, its tensile strength is the same 
as that of cast steel. This is less 
than the tensile strength of rolled 
steel. However, by depositing a 
sufficiently large cross section of 
metal, the tensile strength of the 
weld can be built up to an amount 
equal to, or greater than, the 
strength of the plates joined. Ifa 
bead equal to 15% of the thickness 
of the plate be deposited on both 
sides, the strength of the weld will 
be equal to the strength of the plate. 


Strength of Lap Welds 

In a lap weld subjected to tension 
the weld is subjected to a bending 
stress as well as a tensile stress. The 
amount of the bending stress de- 
pends on the thickness of the plates. 
In practice it has been found that 
when a bead of welding metal equal 
to the thickness of the plates is de- 
posited on both edges, as shown in 


the illustration, the strength of the 
weld will be approximately equal to 
the strength of the plates joined. 


Fig. 177 
A single lap joint should not be used to 
join thick plates. The stress on this joint 


is not pure tension, but a combination of 
tension and bending. 


Fig. 178 
In riveted construction it is customary to 
use a butt strap as shown. 


Fig. 179 
In arc-welded construction it is only 
necessary to weld both sides of the plates. 
This joint is as strong as the members 
joined. 

In a lap weld the metal comprising 
the weld is in shear. It may be in 
either transverse shear or longitu- 
dinal shear. Experiments have 
shown that welds in transverse shear 
are stronger than welds in longitu- 
dinal shear. 

In sketch 180, the metal deposited 
along the edge c is about 30% 
stronger than the same metal laid 
along edges d or e. 


Metal deposited along edge c is about 30 
percent stronger than the same metal de- 
posited along edge d or e. 


Page Iii 


20000 
19000 TENSION OF FLUSH TOPWELD 
—— 
Sea ae eae revel 
leas re CROSS SHEAR 


an 
AS je i 
Bats 


fe SSRREeee 
Teel ey 3 ve Tk G 
8 1 4 i 16. se (A) 


Fig. 181 


Rupturing force per linear inch of weld. 


Page 112 


Strength of Fillet Welds 


The strength of fillet welds de- 
pends entirely upon the amount of 
metal deposited. If sufficient metal 
is deposited on both sides of the 


plate, the strength of the weld 
can be made far greater than 


the strength of the plates them- 


selves. 


Strength of Rivet Welds 


The rivet weld is not used pri- 
marily for strength. It is not pos- 
sible to obtain a 100% joint by 
this process any more than a 100% 
joint can be made by ordinary rivet- 
ing. The rivet weld is stronger 


than ordinary riveting, because 
the welding metal completely fills 
the hole and is integral with the 
plates themselves. There is no 
possibility of weaving in a rivet- 
welded joint. 


Rupturing Force Per Linear Inch of Weld 


The chart reproduced on Page 
112 shows the rupturing force per 
linear inch of weld. From this 
chart the proper length of weld for 
any style of joint can be computed. 
The values given are conservative 
and designs based upon them will be 
amply safe. Since these are ruptur- 
ing forces they correspond to ulti- 
mate strength given in tables on 
strength of materials. In applying 
these figures the customary factor of 


safety should be used as in the case 
of ultimate strength of other mate- 
rials. In the case of welds less than 
6” long it is customary to add 4” 
to the theoretical length of weld to 
allow for the starting and stopping 
of the arc. The curves for both 
cross shear and longitudinal shear 
are based upon bead sections con- 
vex outward as shown in Figure 
181. Greater convexity will in- 
crease the strength and lesser con- 
vexity will decrease the strength. 


Page 113 


EFFICIENGY OF KWVEIEL [= 


MGI wg « WOW y 
— any, 


RIVETS /17 RIVETS 1/7 


DR/FAL\ P/AY 


PUTLH >| EFFICI- P/TLH | EFFICT- 
HYCHENVILY~ 77 \WILHES|LEVILY-77 


SIPIGLE RIVETEPR STEEL SOUTTS 


2 w |_& 
YHA SD fF 
cS 

© fe IN yee 
~~ 

ve) mH Ps OO a Ia 

HD |p BV [8 [S/S 

\ GD |) 


| aes | 
345 


MN KN AN 
Q&A A 
Wy IN \ 


(y 
pS) 
% 


N 
Oy 


N w RNY 


yd 


ww 
LD 


\ 


Ler p=Ftren Or kivars, os Diarra rer Ot Ceivenkivers s 7° LPCIt 
gency 2a Kerio le FrRen6TH OE Solyt [OFTRENETH LF 
Soup Farres Then a= 3%x.50 


Fig. 182 


Page 114 


Comparative Strength of Welded and Riveted Joints 


In an-analysis of the strength of 
welded joints it is convenient to 
compare the welded joint with the 
corresponding style of riveted joint. 
The simplest form of welded joint 
is the lap weld. This welded joint 
corresponds to a lap riveted joint. 
It may be single lap welded or 
double lap welded just as a joint 
may be single riveted or double 
riveted. 


In a lap-riveted joint there are 
three ways in which failure may 
occur : 


1. The plate may crack along the 
line of rivet holes. 


2. The rivets may shear off. 


3. The plates may tear out at the 
ends. 


In a riveted joint designed for 
maximum strength in tension the 
rivet spacing, size of rivets, and 
distance from end of plate must be 
carefully determined. In practice 
tables are used, based on theoretical 


computations plus the results of 


practical experience. Such a table 
is given on page 114. It will 
be seen from this table that the 
efficiency of a properly made riveted 
joint ranges from 45 to 76 percent. 


In welding, the plates to be joined 


- are not weakened by punched holes. 


Therefore, it is apparent that two of 
the three causes of failure in riveted 
joints are avoided by welded con- 
struction. The plates at the joints 
are full strength, and are no more 
liable to fail at the joint than at any 
other point along their lengths. 


Fig. 183 


Riveted joints fail in three ways. Plates 
crack along line of rivet holes. Rivets 
shear off. Plates tear out at end. 


Page 115 


Fig. 184 


Kiln Accelerator Fan, manufactured by 
Robinson Ventilating Co., Pittsburgh, Pa. 
The fan blades, formerly of cast iron, are . ; 

now arc-welded steel. Welding has super- Fig. 185 


seded riveting throughout. 


Fig. 186 
Seat assembly for Ford chassis completely arc welded by W. C. Nabors, Mansfield, La. 


Page 116 


A handy table is reproduced below, 
showing the size of weld, equiva- 
lent in strength to rivets of various 
sizes. 

In computing the size of welds 
equivalent in shearing strength to 
rivets of various diameters, the 
same factor of safety has been used 
in both cases. 


These values for length of weld 
are derived from the curve of cross 
shear in Figure 181. A safety factor 
of 4 was used and a %4” added to 
the theoretical length. In case rivets 
are to be replaced by weld in longi- 
tudinal shear the table may be re- 
computed by the use of the curve 
for longitudinal shear in Figure 181, 
“or substantially the same results 


Fig. 187 


Cross section of a riveted joint. Note 

how, in cooling, the rivets have shrunk 

away from the sides of the rivet holes. 

This illustrates one great weakness in 
riveted construction. 


may be gotten by simply increasing 
the length of weld given in the above 
table by 30%. 


SHEARING VALUES FOR WELDS AND EQUIVALENT SIZE OF RIVETS 


ly” Bead 


Value 
inch of 


Value 
Bead, Ibs. 


inch of 


Rivet at 10000 
Bead, Ibs. 


Size of Rivet, 
inches 
Length of Bead, 


Shearing Value of 


Shearing 
per 
Shearing 
per 


4” added to theoretical length of weld. 


ts Bead 


Length of Bead. 


34’ Bead 


Value 
inch of 


Value 
Bead, lbs. 


inch of 


Value 
Bead, lbs. 


inch of 


Bead, lbs. 


Shearing 
per 
Shearing 
per 
Shearing 
per 


3200 
3200 
3200 | 3 


1%| 4100 
2341 4100 
4100 


Page 117 


= 


Hige 


9078 lbs. 
pela failuce 


22,000 /bs. 
-& ers G. Hicé 


Fig. 188 ; 


Tension tests of welded and riveted joints. 


Page 118 | 


Tests of Welded Joints 


to the same test as the riveted sec- 
tion and after 24,900 alternations, 
failure occurred in the channel out- 


A striking example of the super- 
iority of welded joints over riveted 
joints, where subjected to alternat- 


side the weld. 


ing stresses, is illustrated by the two 
tests described below. 


For the first test a section was 
made up of the same material and 
by the same methods as used in the 
manufacture of a well known motor 
truck frame. This section was sub- 
jected to repeated alternating stress 
by mounting it on a shaper base as 
shown in the illustration. At 200 
alternations of the stress the top 
rivets in the gusset plates became 
loose. The second and third pairs 
of rivets in the gusset plates failed, 
as shown on the chart below. Next 
the five rivets in the angle connected 
to the channel worked loose. Fol- 
lowing this the two upper rivets at 
the far end of the I-beam section be- 
came loose, and failure occurred 
where the channel section had been 
weakened by the rivet holes. 


Fig. 189 


In the welded test sample the 
angle stiffener was omitted, as ex- 
perience had shown that it was not 
required. The piece was subjected 


Fig. 190 


FESULTS OF TEST. SYIOW/NS PROGRESSIVE PAHILURPE QF FIVETEO PIECE 
ANO HIGH RESISTANCE TO FAILUPE OF ELEETRIC ARC WELDED PIECE 


Se oe 1 -----| 
ee SN | 


feat | ae Pee wa | 
. eee ad 
8 i 
—— 
w 
S eee pase 
w L easy Leas | 
& arse ce ae 
Fy Svar oc 
BN 59 
ee 
eo 


4000 23.000 


Alternating stress test riveted joint—welded joint. 


Page 119 


Since in riveted construction, the 
actual strength of a joint is mate- 
rially lessened the instant that one 
rivet works loose it is apparent that 
200 alternations in the stress were 
sufficient to cause incipient failure. 
On the other hand in the welded 
construction, the joint proved 


stronger than the members joined. We 

The results of a similar test with a Bek 
simple T-section are shown graphic- 
ally in the chart below. Here again 
the riveted joint failed where the 
members had been weakened by 
rivet holes. The welded joint 
proved far stronger and failure oc- 


curred outside the weld. 


Fig. 193 


FPESULTS OF TEST: SHOW/NG PROGRESSIVE FA/LUAE OF AWETED 
VOINT AND HIGH DEGHEE OF AIG/OITY OF WELDED JOINT 


wee) | 
_| | | | | 


s | 
. x B4R FA/ILEO \THRU 
N) PRIVET HOLES GAP FAILED 
Ra 
Ny 
kt 


1000 3000 SOOO HO 6200 F000 QE SHO 
Fig. 194 | 


Alternating stress test riveted joint—welded joint. 


Page 120 


Welded Joints Are Reliable 


Naturally the human element en- 
ters into the construction of a welded 
joint just as it does into the con- 
struction of a riveted joint. A 
riveted joint, even though correctly 
designed, may not develop its full 
strength because of improper work- 
manship. It very frequently hap- 
pens, particularly in field riveting, 
that the holes in two members do 
not register properly. It is neces- 
sary then to ream the holes before 
the rivet can be driven. This re- 
sults in an oval shaped hole which 
the rivet can not possibly fill. The 
rivet itself is deformed and the 
joint will be far below its com- 
puted strength. In structural work 
it is frequently necessary to force 
the rivet holes into alignment by 
driving drift pins. This means that 
when the joint is complete there will 
be an additional stress on it, due to 
the tension in the member forced 
into place. There is the additional 
danger of driving burned rivets or 
rivets which are too cold. Both of 
these are well recognized causes for 
failure in riveted joints. 


It is a fact that because of lack of 
familiarity with the welding process 
there exists a prejudice on the part 
of some people against welded con- 
struction. If one will stop to realize 
that every time one rides on a steam 
train his very life depends on the 
strength of arc welding, it will be 
seen that this prejudice is unwar- 
ranted. Arc welding is used ex- 
tensively in the manufacture and 
maintenance of steam locomotives. 
The boiler flues are welded into the 
back flue sheets, broken cylinders 
and even broken main frames are 
repaired by arc welding. It would 
be difficult to conceive a more severe 
test of dependability, or a test 
where a failure would be more dis- 
astrous. 


Welded joints can be inspected 
with the same degree of certainty as 
riveted joints. Visual inspection 


can not be depended upon one hun- 
dred percent in either case. If 
proper workmanship is employed a 
welded joint can be relied on to de- 


velop its theoretical strength. 


Fig. 195 


Arc welding the main frame on a passenger locomotive. 
found of the dependability of arc welding! 


What greater proof could be 


The railroads were among the first to see 


the possibilities of arc welding. 


Page 121 


Fig. 196 


The frame for this foundry sand cutting machine was formerly made by riveting at a 
cost of approximately $200.00. Arc welding reduced this cost to less than $60.00. 
Manufactured by the Production Equipment Co., 1521 Windsor Ave,, Cleveland, Ohio. 


CHAPTER VI 
The Speed and Cost of Welding 


RC welding is cheaper than riv- 
eting and cheaper than any 
other method of welding. This is 
true because in arc welding, power 
is utilized more efficiently than in 
any other method of joining metals. 
The power required to operate an 
arc welder is just about equal to the 
power required to operate one com- 
pressed-air riveting gun. The labor 
cost is of course much less than for 
riveting as one welder does the work 
of an entire riveting crew. 
Arc welding utilizes power more 


Tv * 
8 Pitre 
Fig. 198. Comparative costs of riveting, gas welding and arc welding based on 


continuous operation. 


efficiently than gas welding because 
the electric current is transformed 
directly into heat and the heat is 
developed within the metals to be 
welded. In gas welding, heat is 
generated by the burning of gas 
which was originally produced by 
electricity. This process of trans- 
forming electric current into heat is 
indirect and therefore wasteful. 
Furthermore, the heat is developed 
at a point outside the weld and a 
large part of the heat of the flame is 
dissipated. 


Page 123 


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INCHES OF W. ELD Pade oh Wf2b/es 
Fig. 199 


‘Piece work speed for horizontal fillet welds with metallic arc. No allowance for set 
up or fatigue included. 


"OEE "ON JOA M3N a ¥3883 PF 1953NIy 


Page 124 


Cost of Arc Welding Compared to Other 
. Methods of Joining Metal 


The chart reproduced in figure 
198 shows the relative cost of joints, 
single riveted, double riveted, gas 
welded and arc welded. The cost 
is given in dollars per foot of seam 
for metal of various thickness from 
¥% inch to 1 inch. . It will be seen, 
throughout the entire range, arc 
welding is the least expensive pro- 
cess. The costs given on this chart 
(Fig. 198, page 123) are direct costs 
and do not include any charge for 
depreciation or upkeep. 

Gas welding is frequently used in 
repair shops where welding is inci- 
dental to the general repair business. 
This is because the first cost of 
equipment for gas welding is less 
than the cost of an arc welder. 
While the investment in an arc 
welder is not large (usually less than 
$1000) it is still an item for the 
small shop. 


DAILY COST 


Cc ae A 8 OF TE On 


However, when the amount of 
welding is more than three linear 
feet of weld per day, arc welding is 
more economical than gas welding. 
This is shown graphically by the 
chart reproduced in figure 200. On 
this chart is a curve showing the 
fixed charge at 17 cents per day. A 
second curve shows the daily cost 
of gas welding with the fixed charge 
reduced to zero. ‘That is, it is as- 
sumed that the equipment for gas 
welding cost the user nothing. The 
fixed charge for the arc welder is 
taken at 60 cents per day. Even on 
this basis it will be seen that arc 
welding is far less expensive for 
production welding. 


The chart figure 198, showing the 
cost of arc welding per foot of seam 
for various thicknesses of metal, is 
sufficiently accurate for purposes of 
comparison. It is, however, not 
suitable for estimating purposes. 


10 


Feet of 14” weld per day. 


Fig. 200. Daily cost of operating a gas welder and an arc welder. 


Gas welding costs 


shown both with and without fixed charges. 


Page 125 


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poe eee al aa 
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a z& o 
= 7 CS SIEE HULLET @ 
Fig. 201 


Piece work apg for horizontal fillet welds with metallic arc. No allowance for set 
up or fatigue included. 


if 
pays “esas 


Page 126 


The Speed of Welding 


It is important to know that the 
speed of welding and consequently 
the cost of any job can be estimated 
in advance with the same degree of 
accuracy that the cost of any ma- 
chining operation can be estimated. 
Most production welding is done on 
a piece-work basis and the problem 
of determining rates for any kind 
of welding becomes very simple 
when the principles are understood. 
The following paragraphs give the 
theory of determining welding 
speeds: 

The time required to make a weld 
varies directly with the rate at 


which the metal is melted. 

It is therefore necessary, first, to 
know the rate at which an arc welder 
will deposit metal. This is found 
by reference to a curve such as is 
reproduced in figure 202.* 

The nature of the weld determines 
the size of the electrode and also 
the proper current to be used. 
Knowing these, the amount of metal 
deposited per hour is read directly 
from the curve. 

Divide the amount of metal to be 
deposited (in pounds) by the rate 
of deposition and the result is the 
time required to make the weld. 


DIAMETER OF ELECTRODE 


“ 


H 


+A 


wy 


POUNDS OF| ME7HWL mle 
PER WOUR 


N 


25 50 75 100 125 


150 


175 200 225 250 275 300 


Fig. 202 
Pounds of metal deposited per hour by metallic arc. 


*NOTE—The rate at which metal is deposited is not the same for all makes of arc welders. 
The curve reproduced in figure 202 shows the rate of deposition for the Lincoln Stable-Arc 


Welder manufactured by The Lincoln Electric Co. 


It should not be used in computing the 


speed of welding with any other make of arc welder as all arc welders are not equally efficient. 


Page 127 


ZZ 


a 


|e ee ee 
LATERL | 
7 t 2) oa, 


2 


eek | eRe 
Pa 
ney 


Fig. 203 
Piece work speed of welding 60° double bevel. Metallic arc. 


Page 128 


Curves Showing Speed of Welding 


In practice it is usually not neces- 
sary to go through all of this compu- 
tation to determine the speed of 
welding as the figures have been 
worked out for all typical welds. 
Curves reproduced in this chapter 
show the speed of welding for vari- 
ous styles of welds. The time re- 
quired to make any ordinary weld 
can be read directly from these 
curves.* 

No allowance is made for set up 


time or for fatigue of operator in 
these curves. Naturally the time 
which the operator is actually de- 
positing metal will vary with the 
nature of the work.’ An average 
would probably be about sixty per- 
cent: 

The person in charge of piece 
work rates will quickly learn what 
percentage of actual operation can 
be expected for different classes of 
work, 


*NOTE—These curves are based on the rate at which The Lincoln Stable-Arc Welder will 
deposit metal and will be found very accurate for determining welding speeds with that machine. 
These curves should not be used in determining the speed of welding with other machines for 


reasons explained in the previous foot note. 


Fig. 204 


Eight and three-quarter hours were required to rivet the drum on this concrete mixer. 


It is now arc welded in five hours. 


This is one of many applications of arc welding . 


made by The T. L. Smith Co., Milwaukee, Wis. 


Page 129 


MIO of. 


eae 
LISS 


TLE 
TET 


2 N " 


Fig. 205 
Piece work speed of welding 60° single bevel. Metallic arc. 


Page 130 


The Cost of Welding 


The cost of welding is found by 
multiplying the time required to 
make the weld by the hourly rate. 
The hourly rate includes: 

Cost of labor. 

Cost of welding wire. 

Cost of current. 

The cost of labor is the largest 
item for all classes of welding. 
Rates vary widely but the rate of 
80 cents per hour is assumed for 
this discussion. 

The cost of welding wire is the 
next largest item. This varies di- 
rectly with the amount of metal de- 
posited. When welding continu- 
ously a welder operating at 250 am- 
peres, with 1% inch electrode, will 
deposit about 61% lbs. of metal per 
hour. This figure should be in- 
creased by 20% to cover waste, 
making the amount of welding wire 
required for continuous operation, 
7% \bs. per hour. At 8 cents per 


pound, the cost of welding wire 
would be 60 cents per hour. 

In actual practice the welder will 
operation. 


not be in continuous 


Some time must be allowed for 
setting up work and for fatigue of 
operator. Assuming that the weld- 
er is in actual operation 60% of the 
time, the cost for welding wire will 
be 36 cents per hour. 


The cost of current is the smallest 
item. This cost varies with the 
power rate per K. W. H., and the 
percentage of time that the welder 
is in actual operation. Assuming a 
power rate of 2 cents per K. W. H., 
the cost of power for continuous 
operation, will be approximately 13 
cents per hour. The sum of these 
items gives an hourly rate of $1.29 
for 60% operation, 


Sixty per cent operation was 
chosen for the discussion above be- 
cause it represents average condi- 
tions. There will frequently be 
cases where the percentage of opera- 
tion will be much higher than this. 
When this is true, the hourly rate 
will increase slightly as more weld- 
ing wire and more power will be 
required. 


Fig. 206 


Eight hours were required to drill, fit up and rivet the load bucket illustrated on the 


left. 


The welded bucket was completed in 414 hours,—a net saving of 3, hours. 


Photographs and data furnished by the W. E. Dunn Mfg. Co., Grand Rapids, Mich. 


Page 131 


= 


SP ey Ae 


Fig. 207 
Piece work speed of welding 90° corner weld. Metallic arc. 


Page 132 


Overhead 


g 


The overhead cost includes the 
same elements of first cost of equip- 
ment, cost of floor space, light, heat, 
etc., that are figured for any other 
production tool. There is usually a 
very great saving here. Since prac- 
tically all factories are supplied with 
electricity, there is no space required 


for auxiliary equipment such as air 
compressor, or gas generator, which 
are required for riveting, or gas 
welding. The arc welder takes up 
very little space and in many plants 
is mounted on a portable truck and 
moved from place to place as the 
work requires. 


Method of Figuring the Cost of a Typical Weld 


Fig. 208 


PROBLEM 


Figure cost to make a single lap-welded joint 72 pg ce long, between 
two plates 14 inch thick. 


First Step. Determine time required to make the weld, assuming con- 
tinuous operation. 


This is found by referring to the curves reproduced in figure 199. The 
curve for plates % inch in thickness shows that to weld 12 inches of seam 
requires approximately 514 minutes. 


To weld 72 inches, assuming continuous goon: will require 72/12 
< 5% or 33 minutes. 


Second Step. Determine the percentage of time that the welder will 
actually be depositing metal. 


This depends on set-up time, etc. For this example let us assume 60% 


operation. 
The total elapsed time will then be: 33 & 100/60 or 55 minutes. 
Third Step. Compute cost of the weld. 


Since the hourly rate for an arc welder for 60% operation is $1.29, the 
cost of making the weld described above is: $1.29 & 55/60 = $1.18. 


Page 133 


Fig. 209 


The old tradition that steel pipe would not last underground has been effectually 

killed. Today, by far the greatest amount of land pipe is made of steel. Steel pipe 

is made most economically on automatic arc welders. Here is a stack of 20” diameter 
pipe arc welded by The Lancaster Iron Works, Lancaster, Pa. 


ee Fig. 210 


The National Grave Vault Co. gives three reasons for substituting arc welding for 


riveting in the manufacture of grave vaults. They are: More permanent construc- 
tion, better appearance, and lower costs. This company was among the first to adopt 


, automatic welding. 


. 


Page 134 


CHAPTER VII 
Automatic Arc Welding 


HE automatic arc welder is 

literally a sewing machine for 
steel. By this remarkable machine 
the edges of two pieces of steel plate 
can be joined with the same facility 
that a seamstress joins the edges of 
two pieces of silk. 


In automatic arc welding the 
edges of the plates to be welded are 
held firmly in the proper position for 
welding by a jig or fixture. The 
electrode forming one end of the 
arc is moved automatically along the 
seam or the work itself is moved 
past the electrode at the proper 
speed to insure a perfect weld. Pro- 
vision is made for feeding down the 


ELECTRODE HOLDER 


WORK TO BE WELDED 


electrode, as it 1s consumed, at ex- 
actly the proper rate to maintain a 
steady uniform arc. 


Once the correct speed of feeding 
has been determined it is only neces- 
sary to place the work in position 
and start the arc. 


There is no more spectacular 
operation in the entire field of 
manufacturing. A machine which 
joins solid pieces of steel with a 
joint of equally solid steel, the en- 
tire process unaided by human 
hands, is a far cry from the old 
method of pegging steel together 
with rivets. 


SOURCE 
OF 


CURRENT 


Fig. 211 


Diagrammatic view of Automatic Welding Process. 


Page 135 


Fig. 212 


There are no rivets to rust or corrode in this arc-welded stack, built by The Leitelt 
Iron Works, Grand Rapids, Mich. 


* 


Page 136 


Field for Automatic Welding 


The field for automatic welding is 
wherever similar steel parts are to 
be joined in production quantities. 
The shape of the product, the length 
of weld, the weight or thickness of 
the steel are of minor importance. 
If the quantities are sufficiently 
large, automatic welding will re- 
duce the cost of making joints. 

In addition to the obvious appli- 
cations such as the manufacture of 
gasoline tanks, the automobile in- 
dustry utilizes automatic welding in 
making rear axles, frames for self- 
starter motors and many other 


products. Range boilers and grave 


vaults are welded automatically. 
steel) pipe up to 65, inches in 
diameter has been welded auto- 
matically with astounding savings. 
Crude oil storage tanks of large pro- 
portions are welded by a most in- 
genious self-propelled welding head 
which follows the seams with un- 
canny accuracy and joins each seam 
with a permanent leak-proof joint. 
If steel is to be joined to steel in 
automatic 


production quantities, 


welding should be investigated. 


Fig. 213 


Welding inside seam on small tank. 


Page 137 


Table of Speeds and Costs of Automatic Electric Arc Welding 


———_, 


Joint Before Welding 


(SD rey 


Joint After Welding 


Joint Before Welding 


THe eee 


Joint After Welding 


Gauge of Material 14 12 10 ve 


Speed in Foot per Hour 5 135 105 80 65 
0 


275 300 a 35 


Data for Butt Weld (One Side Only) 


Gauge of Material ... 18 16 14 12 10 rs Yy 3% 1" 5% 34 
Speed in feet per hour} 170 160 150 100 75 60 40 25 17%! 14 10 
Current (Approx.) ...| 275 300 325 350 375 400 450 550 650 700 750 
Size Filler Rod 

GApprom hin. 33 % % 33 is is Ye |x [4x56 | xd | ox34 
Size Carbon (Approx.)| 14 4 Y yy 15 15 x% 4 6 4 4 
Total Cost per Foot. . |$.0097} .0110] .0119] .0187] .0252] .03 .048 085.) 23317) sl 7021222383 


YY \y yy 4 
.0084 a al Wee .0158 .0200 


NOTE: On lap weld no filler rod is used. 


ey 


Joint Before Welding 


=A [— 


Joint After Welding 


4 
45 
400 


i6 
.0291 


SN wt wong 


NOTE: On edge weld no filler rod is used. 


These costs include Power at 3c per K.W.H., Metal Electrode at 8c per pound, Carbon Electrode 
at 13c each, Labor at 60c per hour and cover welding time only. 


Owing to varying conditions in different plants it is manifestly impossible to give actual costs, includ- 


ing set up time. 


If the work is properly organized the arc should be running 75 to 80 percent of the time. 


Page 138 


The Automatic Welder Makes Perfect Welds 


. In quality of work the automatic 
welder equals or betters the work 
of the most experienced manual 
welder operator. The length of the 
arc and the rate of feeding are con- 
. stant and the welds produced are 
uniform in strength and appearance. 


The amount of current required 
for each job and consequently the 
amount of heat for perfect welds, 
can be determined once for all. An 
automatic welder can be set up for 
a particular job with the same de- 
gree of exactness that the indexing 
head on a milling machine can be 


set for cutting gears. 


Fig. 215 


Upper and lower side of seam made by 
automatic arc welder using carbon elec- 
trode. Note how the weld is reinforced 
on the under side. This is made possible 
by the use of copper strips which in effect 
form a mold for the molten metal. 


Fig. 216 
Range boilers produced by Automatic Arc Welding. Note the edge welds on bottom. 


Page 139 


Welding the girth seams on oil tank using a rotating fixture. 


Speed of Automatic Welding 


An automatic welder never tires. 
This is one reason for the greater 
welding speeds obtained by auto- 
matic welding over manual welding. 
The speed of feed can be adjusted 
for maximum production and this 
speed can be maintained without in- 


terruption. This, however, is not 
the only factor which accounts for 
the high speeds possible in auto- 
matic welding. The greatest factor 
is the utilization of the carbon elec- 
trode arc instead of the metallic 
electrode. 


Page 140 


Fig. 218. Automatic welding on gravevaults. 


Carbon Electrodes Are Used for Automatic Welding 


The most successful automatic 
welders utilize the carbon electrode 
process. As explained in Chapter 
III, this is a puddling process and 
The heat 


of the arc melts the edges to be 


not a deposition process. 


joined and where additional metal is 
required it is supplied by a filler rod 
which is laid along the seam prior to 
welding. The small pool of molten 
metal underneath the arc is kept in 
bounds by water-cooled copper 
strips which in effect form a mold. 

The edges of the plates to be 
joined and the metal supplied by the 


filler rod are melted simultaneously 


and as the arc moves along the 
seam this molten pool cools and 
solidifies, forming a solid homo- 
geneous weld. By this process 
oxidation is at a minimum because 
only the very small surface of the 
molten metal is in contact with the 
ait. 

Since the edges of the plates and 
the metal added by the filler rod are 
in the molten state at the same in- 
stant and cool at the same time 
there is no possibility of laps or 
seams by this process. 

With a carbon electrode there is 


no limit to the amount of current 


Page 143 


that can be used. With a metallic 
electrode there is a very definite limit 
to the amount of current. This limit 
is the amount of heat which the tip 
of the electrode itself will stand. 


Obviously if it were attempted to ~ 


put a very large current through a 
small metallic electrode the electrode 
would burn up almost instantane- 
ously. 


the 
small currents suitable for weld- 


Even with comparatively 
ing on light material the problem of 
feeding metallic electrodes is much 
more difficult than the feeding of 
carbon electrodes. A much finer 
adjustment is necessary, requiring 
intricate mechanism which is not re- 


quired on a carbon electrode welder. 


Automatic welding with the car- ° 
bon arc is more economical than 
with the metallic arc for two rea- 
sons. First the speed of welding is 
greater, and second, the cost of filler 
metal is less with the carbon arc 
process. 


The speed of welding is greater 
because more heat can be utilized at 
the arc which means that metal is 
melted faster. 


The cost of filler rod is less be- 
cause a smaller amount is used and 
also because the cost per lb. of the 
mild steel rod or strip which is gen- 
erally used in carbon are welding is 
less than the cost per lb. of the spe- 
cially prepared wire which must be 
used in the metallic arc process. 


Page 142 


Twelve Inch Pulley 


Weight Cost 
eecee TOR ee ee Poelbs wer Viaterial 22s oe $7.90 
Labor ee eee 2.99 $10.89 
Matetial.aee ae 31.20 
pteel aa —--- = -=-=-—-+ ~~~ ---- ~~ GTA ky NE i 185 3.05 
Wall Box 
Weight Cost 
UP LATS Ae at ana 35 Ibs. $2.10 
Material... 3. ee. $ .42 
Steel ----------____------------- 14 Ibs Lahore 2S ee 30 he 
Support 
Weight Cost 
CrastmiCOite we ee eee Lk 27 lbs. $2.27 
Material _________ sien We $ .42 
has Do ay i TR se 140 1bs.- oLabor.be see eee 23 65 


Fig. 219 


Striking examples of the substitution of arc welded steel for cast iron. The Baker- 
Perkins Company, Saginaw, Michigan, who developed these applications supplied the 
cost figures. 


Page 143 


‘ 


Fig. 220 


Spherical tank in course of erection by the Chicago Bridge and Iron Works, fabri- 

cators of Horton Steel Tanks. This “Hortonsphere” is arc welded throughout, making 

it the most economical as well as the strongest type of storage tank that can be 
designed. . 


Fig. 221 . 


Mast head fittings built by the Chicago Bridge and Iron Works for use in connection 
with erecting “Hortonspheres.” 


Page 144 


Fig. 222 


Dump cart arc welded by the Euclid Crane & Hoist Company, Euclid, Ohio. 
All permanent joints are arc welded. 


cok : 
ee 


| 
\ a 
j > 
\ 

\ 2, 
\ os 


Fig. 223 


Wrought iron doors in the home of Harry K. Thaw, Pittsburgh, Penna., arc welded 
by the Jansen Art Forging Company, Cuyahoga Falls, Ohio. Arc welding effects 
great economies in the manufacture of ornamental iron work. 


Page 145 


Fig. 224 


Electric heater arc welded by Littleford Bros., Cincinnati, Ohio. 


Fig. 225 


The Detroit Stoker, Detroit, Michigan, have cut manufacturing costs to a minimum by 
arc welding. Coal hoppers, drive chain guards and trench floor plate frames are 
among welded parts shown in this photograph. 


Page 146 


Advertising 
Section 


The Lincoln Electric Co. 


General Offices and Factory: Cleveland, Ohio 
The Lincoln Electric Company, of Canada, Ltd., Toronto-Montreal 


European Representatives: 
Allen-Liversidge, Ltd., London 


Distributing Agencies in all Principal Cities 
EXCLUSIVE AGENCIES WITH STOCK 


Ft. Worth, Texas Houston Seattle Los Angeles 
New Orleans Portland Kansas City San Francisco 


BRANCH OFFICES 


Baltimore Charlotte, N. C. Davenport Indianapolis Minneapolis Pittsburgh 
Boston Chicago Detroit Lancaster New York City St. Louis 
Buffalo Cincinnati Grand Rapids Milwaukee Philadelphia 


Page 147 


ADVERTISING SECTION 
The Equipment for Arc Welding 


LL of the welding on the vari- 
ous products illustrated in this 
manual was done by the Stable Arc 
Welder, manufactured by The Lin- 
coln Electric Company. The Stable- 
Arc Welder is built in a complete 
range of sizes and styles to provide 
for any class of work and any 
operating conditions. 
All of these types consist essen- 
tially of: 
1. A standard motor driven by 
the shop power lines. (This motor 


furnishes the power for driving the 
welding generator. Where electric 
power is not available, gasoline en- 
gine or belt driven welders are 
supplied. ) 

2. A specially. wound generator 
delivering current at the proper 
voltage for welding. 

3. A stabilizer acting as a reser- 
voir of current. 

4. A control panel with simple 
knife switches and meters for ad- 
justing the amount of welding heat. 


Fig. 226 


As built in the larger sizes. 


Stationary panel type. 


Page 149 


The Stable-Arc Generator 


The design and construction of 
the welding generator partly ac- 
counts for the uninterrupted flow of 
heat which is possible with the 
Stable-Arc Welder. This generator 
is wound with what is termed a 
bucking series field which with the 
laminated steel frame produces a 
welding current with the proper 
characteristics described in the pre- 
vious chapter. 


Not only the pole pieces but the 
complete magnetic circuit of the 
Stable-Arc Welder is laminated, 
that is, built up of steel laminations 
or sheets. The electrician will 
readily understand that this type of 
construction permits a very rapid 
change in the magnetism or “flux 
density” and this in turn makes it 
possible for the electric current to 
adjust itself instantly to any de- 
mand. 


Fig. 227 
Stationary platform type. Built in 200 and 300 ampere sizes. 


Page 150 


The Stabilizer 


In addition to the laminated steel 
generator the Stable-Arc Welder is 
provided with a stabilizer which, in 
electrical terms, is simply an in- 
ductance in the welding circuit. 
This stabilizer acts on the electric 
current much like a flywheel does 
on any other piece of machinery. It 
stores up energy which permits the 
machine to take care of extraordi- 
nary demand without difficulty. 


A Steady Arc Means Good 
Welds 


Because of the laminated frame 
construction and _ stabilizer, the 
Stable-Arc Welder produces an arc 
which is steady and easy to main- 
tain. This means better and faster 
welding. Frequent breaking of the 
arc and the necessity of frequent 
starting produce a brittle and porous 
condition in the weld. The best 
welds are made where the arc is 
kept steadily in operation and the 
metal thus deposited is homogeneous 
and strong. 


Fig. 228 


Gasoline engine driven type. 


Built in 200 and 300 ampere sizes. 


Page 151 


Methods of Driving the Welding Generator 


The Stable-Arc Welder can be 3. Belt drive. 
operated by any of the following In the majority of cases electric 
SSE current 1s available wherever weld- 

1. An electric motor operating on ing is to be done. This is the most 
either direct or alternating current satisfactory and economical method 


of any standard voltage. of operating the welder. 


2. A gasoline engine direct con- 
nected to the welder. 


bd 


Fig. 229 
Belted type. Built in all sizes. 


Page 152 


Types of Stable-Arc Welders 


Stable-Arc Welders are built in 
sizes of 200 amperes to 1200 am- 
peres, rated in accordance with the 
standards of The Electric Power 
Club. They are mounted in various 
different ways. to suit different op- 
erating conditions. 


The various types are: 
1. Stationary Platform Type. 


This type is built in 200 and 300 
ampere sizes. The entire equipment 
is mounted on a structural steel base 
and is furnished completely wired 
and ready for operation. 


2. Portable Truck Type. 


This type is built in 200, 300 and 
400 ampere sizes. The entire equip- 
ment is mounted on an all-steel truck 
which can readily be moved to the 
work. This type is also completely 
wired and ready for immediate use. 

3. Belt Driven Type. 


This unit is built in all sizes. The 
equipment consists of generator, 
stabilizer, control panel, and neces- 
sary wiring. The driving motor is 
omitted. A pulley mounted on the 
shaft of the generator permits driv- 
ing from the countershafting. 

4. Gasoline Engine Driven Type. 

This unit is built in 200 and 300 
ampere sizes. A 4-cylinder heavy- 
duty engine is direct connected to 
the welding generator by a large 
flexible coupling. The entire equip- 
ment is mounted on a rigid arc- 
welded steel base. 

5. Stationary Panel Type. 

This unit is built only in the 
larger sizes. The motor and gen- 
erator are mounted on a steel base. 
The control panel and stabilizer are 
separate and can be placed in the 
most convenient location for pro- 
duction work. 


Fig. 230 


Portable truck type. 


Built in all sizes. 


Page 153 


Automatic Stable-Arc Welders 


Automatic Stable-Arc Welders 
have been built in a wide variety of 
forms for highly special products. 
To describe all of these would un- 
necessarily complicate this work. 
All forms consist fundamentally of 
the following items: 

1. Fixture for holding work in 
place. These fixtures generally con- 
stitute the base of the automatic 
welder serving to support the elec- 
trode holder and the feeding mech- 
anism. 

2. Device for moving the arc 
along the seam. In some types of 
automatic welders the arc is moved 
along the work and in other types 


Fig. 23 


the work itself is moved. In every 
case there is provision for accurate- 
ly controlling the speed of the feed 
by a small variable-speed electric 
motor. 

3. Automatic electrode holder. 
This holder automatically feeds the 
electrode down as it is burned away 
in welding and maintains the arc at 
the proper length. 

4. Source of welding current. A 
standard Stable-Arc Welder set 
furnishes the power for the auto- 
matic welders. The steady unin- 
terrupted flow of heat which is de- 
livered by these machines accounts 
for the remarkable output made on 
Lincoin Automatic Welders. 


ae - " ? 


: 


Welding longitudinal seams on steel pipe at the Steel Tank and Pipe Company, West 


Berkeley, Calif. 


Pipe sections are 30 feet long and range from 48 to 60 inches in dia. 


Page 154 


Types of Automatic Stable-Arc Welders 
Horn Type 


The Horn or Mandrel type is il- 
lustrated in figure 232. This ma- 
chine welds outside longitudinal 
seams for cylindrical work such as 
range boilers, steel barrels, pipe, etc. 
Steel plate is rolled into shape and 
the edges to be welded are held 
rigidly in place by clamps. The 
lower clamp is a part of the base of 
the machine. The upper clamp is 


operated either manually or by 
means of compressed air. 

The welding head is driven along 
a horizontal arm by means of a 
small variable-speed electric motor. 
This welding head carries a mecha- 
nism for feeding down the electrode 
as it is consumed. 

Welders of this type are built in 
lengths of 4, 8, 12, 16 and 20 feet. 


Fig. 232 


HORN TYPE OUTSIDE SEAM WELDER 
This type is used for welding the longitudinal seams on range boilers, tanks, barrels, 


pipe, etc. 


It is built in lengths of 4, 8, 12, 16 and 20 feet. 


Page 155 


Base Type 


Figure 233 illustrates the Base 
Type Inside Seam Welder. This 
machine is used for welding large 
pipe or tanks. The operation of 
this machine is identical with that 
of the Horn Type except that here 
welds are made on the inside. Be- 
cause of the large size of the work 
handled, the holding clamps are 
operated hydraulically. The Base 
Type Welder is built in lengths of 
20, 24 and 30 feet. It will handle 
pipe 40 inches in diameter and up. 


Fig. 233 


Base type inside seam welder. This type is made in lengths of 20, 24 and 30 feet. 
It will weld pipe 40” in diameter and up. 


Page 156 


Head Welder 


The Head Welder, illustrated in 


figure 234, is used extensively for 


bottoming range boilers, steel barrels 
and small tanks. The welder makes 
what is known as an edge weld, no 
filler rod being required. The work 
to be welded is mounted on a ball 


bearing rotating table. The weld- 
ing head is carried by a horizontal 
arm supported by a vertical column. 
Provision is made far varying the 
speed of rotation of the table by 
varying the speed of the motor and 
by gear changes. 


Fig. 234 


Head Welder. 


This type is used extensively for bottoming range boilers, tanks, etc. 


It makes an edge weld requiring no filler rod. 


Page 157 


Girth Welder 


The Girth Welder, illustrated in made for controlling the speed of 
figure 235, consists of a rotating fix- rotation to obtain the proper speed | 
ture and a stationary support for of welding. Where it is desired to 
the welding head. The set up tank weld inside seams the Tractor Type 
is mounted on the rotating fixture of automatic is used as described 
and the arc started. Provision is on next page. 


Girth Welder. This machine is used for welding the girth seams of large tanks. The 

tanks are first tack welded and then placed on the rotating fixture. The welding head 

mounted on the arm overhead completely welds the outside seams. For welding the 
girth seams on the inside the tractor welding head is used. 


Page 158 


Tractor Type 


The Tractor Type Welding‘Head, 
illustrated in figure 236, is used for 
a wide variety of work. This de- 
vice carries a self propelling mech- 
anism as well as mechanism for 
feeding the electrode. There is 
also a guide which enables the weld- 
ing head to follow a seam auto- 
matically without manual guidance. 


The operation of the Tractor 
Type is almost uncanny. Used in 
conjunction with a rotating fixture 
such as is described above, this de- 
vice automatically welds the inside 
Its 


girth seams of large tanks. 


speed of travel is adjusted to the 
same rate as the speed of the rotat- 
ing fixture except that it travels in 
the opposite direction. The seam 
passes under the arc and a perfect 
weld results. 


This type of automatic is also 
used for welding longitudinal seams 
on large work such as the bottoms 
and roofs of oil storage tanks. Only 
lap joints are welded by this ma- 
chine. 


Fig. 236 


The Tractor Type Welding Head. This welding head is self propelled by a small 


variable-speed motor. 


It carries the carbon electrode together with the mechanism 


for feeding down the electrode as it is consumed. The tractor is used in connection 


with a rotating fixture, for welding inside girth seams for large tanks. 


It is also used 


for welding longitudinal seams on a great variety of work. 


Lincoln Engineering Service 


The large number of Stable-Arc 
Welders in operation and the re- 
markable work which they are 
doing is a testimonial.tc the -sérvice® ° 
renderéd by Lincolri ° engineers: 
Every manufactutet ccnsideritig re-: 


ing is urged to submit his problem 
to the engineering staff of this com- 
Pans Plein eexperictice sie rede. 

igning covers a vast range of prod- 
“ucts. They’ are prepared to assist 
manjutactarers i in redesigning and in 


designing his orcducts to take ad-'»» working out production problems of 


vantage of the economy of arc weld- 


all sorts in connection with welding. 


Page 159 


INDEX 


A 

wistoumatic “Welding.” ..ta.cs.encee 135 
B 

BABOS Sos dati ein GOL eee 65, 67 

Botlers,. “Welded. .0 0 tok act se tee 33 

butt? Welds, Strength cor... asks 111 
Cc 

Sarbon Are: Welding tides eee sk. ce 47 

Carbors Blectendes:.inccaiut materi cee tees 47, 141 

Cast Iron Compared with Steel...cccccccccocees bee eG: 

Cast il ron, Stifinese mar no noe Pay CAI 

Cast Iron, Safety” Factors:iis ccc kc 25 

Cast Iron, Strength in Bending.......ccccsse 29 

Cast Iron, Strength in Compressionneee...c00 23 

Cast Iron, Strength in Tension......ccccccccccssoee 27 

Cast-Iron, Structure. Of 2-2, .nhiec nn 23 

Costo£ | Weldinw iweriuiee ns te ee 123 
D 

Designs, Developments of N€Weeecccccccccccscssee 9 
E 

Equipment for Arc Welding..eccccccccccssccccsces 149 
F 

Fillet Welds, “Strength “ofc 4.4006..04.) 113 

Fixtures, Are Welded... cdscctotecsscsconecoccc 103 
G 

kong Welding, Cost often eee 125 
J 

Jigs; Sado wW elded ip lanwkohn a eee 103 
L 

Lap Welds. Straarth. Gf. «2-4 o eee 111 

Rather alD Steel oc tem oe) 6 eee 75 
M 


Maintenance of Arc Welding Equipment.... 49 


Maintenance, Application of Arc Weld-: 
MILES EO Ss ioesragienctsdinvecosetas seston: othe eee 107 
Metallic Ave. Welding7.s..05......0 47 


P : 
Patterns, Elimination. Ofpeuws.2e ee 11 
R 
Rivet Welds; Strength Ofscccjsecoecserssssecreosecss 113 
Riveted Joints, Efficiency totie04 See 114 
Riveted Joints, Strength Compared to 
Welded  iscctscccasasenecstvssternee aan a Le 
Riveted Joints, Inspection Of.........c0.sescseccsceeos 121 
Riveted Joints, Reliability “Of ....c:cccessssssccose Dod 
Riveting, Cost of..:.i.cis eee Re 
Rivets, Shearing - Valuéuvia.c eee 117 
Rupturing Force, Linear Inch of Weld..112, 143 
Ss 
Safety Factors, Steel and Cast Iron............ 25 
Speed -of Welditig:....c.:cas8ese eee 123, 
Stabilizer. ..:sccissesevetasee eee Ae ey | 
Steel Cost Compared with Cast Iron........ 5 
Steel Compared to’ Cast” Iron.a. aoe Sy es 
Steel, Stiffness’ (6f.ci..dtccee eee ei Ar) 
Steel, Strength “of. eee Sees 
Steel, Strength’ in Bendingicc. oe 53.25 
Steel, Strength in Compression..........cccssses Ze 
Steel, Strength in Tension.cs...u5. ee 527 
Steel, Structure. Of), c.1,000cce ee 23 
Steel Structures © ....dcsssessiecizue eee 97 
Strength of Welditig,...i..:.0n eee 111 
T 
Tanks, Welded..is,.csccusueeeec eee 23 
Tool Room, Arc Welding in.22)..Jateeaee 103 
Ww 
Welded Joints, Inspection? of.4,..0.4055 eee mie! 
Welded Joints, Reliability of....5.250.0:0e 121 


Welded Joints, Strength Compared to Riv- 


CLING — breciasesecsos sdatecdssaneieeeee ee 115 
Welded Joints, Tests of. ....5.0.50 ee 119 
Welds, Shearing Values.ic....cccscscreeuse kee tay, 
Welds, Types: O£,..ccsccssacecsstecr ties sent ee 51 
Welds, Typical Short) Cats.2.) 5 91, 92, 94 
Welding, Automatic. <ccucagu-eaeee nee 135 
Welding, Automatic Speed and Cost Tables 138 
Welding, Forge or FPire,c.uc:.cueeee ee 55 
Weldings, Oxy-Acetylene or GasS.......c.csssees 55 
Welding, Resistance’ ..:.ccne eee ZS 
Welding, Thermit .ccjus.quoee 55 
Wheels: . issneseecscsennaasquuaschecssaee tae eneen an 87 

Form 204-A 


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